Radial expansion of tubular members

ABSTRACT

An apparatus and method for coupling a tubular member to a preexisting structure. The tubular member is anchored to the preexisting structure and an expansion member is displaced relative to the tubular member to radially expand the tubular member.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. application Ser. No.10/303,992, filed Nov. 22, 2002, attorney docket no. 25791.38.07, whichis based on a National Phase of the International Application No.PCT/US01/19014, filed Jun. 12, 2001, attorney docket number 25791.38.02,which is based on U.S. Provisional Application Ser. No. 60/212,359,filed on Jun. 19, 2000, attorney docket number 25791.38, the disclosureof which is incorporated herein by reference.

This application is a divisional of U.S. application Ser. No.10/303,992, filed Nov. 22, 2002, attorney docket no. 25791.38.07, whichwas a continuation-in-part of the following co-pending patentapplications: (1) U.S. utility patent application Ser. No. 09/852,026,attorney docket no. 25791.56, filed on May 9, 2001, which was a divisionof Ser. No. 09/454,139, attorney docket no. 25791.3.02, filed on Dec. 3,1999, which claimed the benefit of the filing date of U.S. provisionalpatent application No. 60/111,293, attorney docket no. 25791.3, filed onDec. 7, 1998; (2) U.S. utility patent application Ser. No. 09/510,913,attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimedthe benefit of the filing date of U.S. provisional application No.60/121,702, filed on Feb. 25, 1999; (3) U.S. utility patent applicationSer. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10,2000, which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/119,611, attorney docket no. 25791.8; (4) U.S.utility patent application Ser. No. 09/969,922, attorney docket no.25791.69, filed on Oct. 3, 2001, which was a continuation of U.S.utility patent application Ser. No. 09/440,338, attorney docket no.25791.9.02, filed on Nov. 15, 1999, which claimed the benefit of thefiling date of U.S. provisional application No. 60/108,558, attorneydocket no. 25791.9, filed on Nov. 16, 1998; (5) U.S. utility patentapplication Ser. No. 10/169,434, attorney docket no. 25791.10.04, filedon Jul. 1, 2002, which claimed the benefit of the filing date of U.S.provisional patent application No. 60/183,546, filed on Feb. 18, 2000;(6) U.S. utility patent application Ser. No. 09/523,460, attorney docketno. 25791.11.02, filed on Mar. 10, 2000, which claimed the benefit ofthe filing date of U.S. provisional application No. 60/124,042, filed onMar. 11, 1999; (7) U.S. utility patent application Ser. No. 09/512,895,attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claimedthe benefit of the filing dates of U.S. provisional application No.60/121,841, attorney docket no. 25791.12, filed on Feb. 26, 1999 andU.S. provisional application No. 60/154,047, attorney docket no.25791.29, filed on Sep. 16, 1999; (8) U.S. utility application Ser. No.09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000,which claimed the benefit of the filing date of U.S. provisional Ser.No. 60/121,907, attorney docket no. 25791.16, filed on Feb. 26, 1999;(9) U.S. utility patent application Ser. No. 09/588,946, attorney docketno. 25791.17.02, filed on Jun. 7, 2000, which claimed the benefit of thefiling date of U.S. provisional patent application Ser. No. 60/137,998,attorney docket no. 25791.17, filed on Jun. 7, 1999; and (10) U.S.utility patent application Ser. No. 09/559,122, attorney docket no.25791.23.02, filed on Apr. 26, 2000, which claimed the benefit of thefiling date of U.S. provisional application No. 60/131,106, attorneydocket no. 25791.23, filed on Apr. 26, 1999. Applicants incorporate byreference the disclosures of these applications.

This application is related to the following co-pending patentapplications: (11) U.S. utility patent application Ser. No. 10/030,593,attorney docket no. 25791.25.08, filed on Jan. 8, 2002, which claimedthe benefit of the filing date of U.S. provisional application No.60/146,203, attorney docket no. 25791.25, filed on Jul. 29, 1999 andU.S. provisional application No. 60/143,039, attorney docket no.25791.26, filed on Jul. 9, 1999; (12) U.S. utility patent applicationSer. No. 10/111,982, attorney docket no. 25791.27.08, filed on Apr. 30,2002, which claimed the benefit of the filing date of U.S. provisionalpatent application Ser. No. 60/162,671, attorney docket no. 25791.27,filed on Nov. 1, 1999; (13) U.S. utility patent application Ser. No.10/089,419, attorney docket no. 25791.36.03, filed on Mar. 27, 2002,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/159,039, attorney docket no. 25791.36, filed on Oct.12, 1999 and U.S. provisional patent application No. 60/165,228,attorney docket no. 25791.39, filed on Nov. 12, 1999; (14) U.S. utilitypatent application Ser. No. 09/679,906, attorney docket no. 25791.37.02,filed on Oct. 5, 2000, which claimed the benefit of the filing date ofU.S. provisional patent application No. 60/159,033, attorney docket no.25791.37, filed on Oct. 12, 1999. Applicants incorporate by referencethe disclosures of these applications. This application is also relatedto the following co-pending applications: U.S. utility patentapplication Ser. No. ______, attorney docket number 25791.330, filed on______, U.S. utility patent application Ser. No. ______, attorney docketnumber 25791.332, filed on ______, U.S. utility patent application Ser.No. ______, attorney docket number 25791.333, filed on ______, U.S.utility patent application Ser. No. ______, attorney docket number25791.334, filed on ______, and U.S. utility patent application Ser. No.______, attorney docket number 25791.335, filed on ______.

BACKGROUND OF THE INVENTION

This invention relates generally to wellbore casings, and in particularto wellbore casings that are formed using expandable tubular members.

Conventionally, when a wellbore is created, a number of casings areinstalled in the borehole to prevent collapse of the borehole wall andto prevent undesired outflow of drilling fluid into the formation orinflow of fluid from the formation into the borehole. The borehole isdrilled in intervals whereby a casing, which is to be installed in alower borehole interval is lowered through a previously installed casingof an upper borehole interval. As a consequence of this procedure thecasing of the lower interval is of smaller diameter than the casing ofthe upper interval. Thus, the casings are in a nested arrangement withcasing diameters decreasing in downward direction. Cement annuli areprovided between the outer surfaces of the casings and the borehole wallto seal the casings from the borehole wall. As a consequence of thisnested arrangement a relatively large borehole diameter is required atthe upper part of the wellbore. Such a large borehole diameter involvesincreased costs due to heavy casing handling equipment, large drill bitsand increased volumes of drilling fluid and drill cuttings. Moreover,increased drilling rig time is involved due to required cement pumping,cement hardening, required equipment changes due to large variations inhole diameters drilled in the course of the well, and the large volumeof cuttings drilled and removed.

The present invention is directed to overcoming one or more of thelimitations of the existing procedures for forming wellbores.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, a method of couplingan expandable tubular member to a preexisting structure is provided thatincludes positioning the tubular member and an expansion cone within thepreexisting structure, anchoring the tubular member to the preexistingstructure, axially displacing the expansion cone relative to the tubularmember by pulling the expansion cone through the tubular member, andlubricating the interface between the expansion cone and the tubularmember.

According to another aspect of the present invention, a method ofcoupling a tubular member to a preexisting structure is provided thatincludes positioning the tubular member and an expansion cone within thepreexisting structure, anchoring the tubular member to the preexistingstructure, and axially displacing the expansion cone relative to thetubular member by pulling the expansion cone through the tubular member.The tubular member includes: an annular member, including: a wallthickness that varies less than about 8%, a hoop yield strength thatvaries less than about 10%, imperfections of less than about 8% of thewall thickness, no failure for radial expansions of up to about 30%, andno necking of the walls of the annular member for radial expansions ofup to about 25%.

According to another aspect of the present invention, a method ofcoupling a tubular member to a preexisting structure is provided thatincludes injecting a lubricating fluid into the preexisting structure,positioning the tubular member and an expansion cone within thepreexisting structure, anchoring the tubular member to the preexistingstructure, and axially displacing the expansion cone relative to thetubular member by pulling the expansion cone through the tubular member.

According to another aspect of the present invention, a method ofcoupling an expandable tubular member to a preexisting structure isprovided that includes positioning the expandable tubular member and anexpansion cone within the preexisting structure, anchoring theexpandable tubular member to the preexisting structure and axiallydisplacing the expansion cone relative to the expandable tubular memberby pulling the expansion cone through the expandable tubular member. Theexpandable tubular member includes: a first tubular member, a secondtubular member, and a threaded connection for coupling the first tubularmember to the second tubular member. The threaded connection includes:one or more sealing members for sealing the interface between the firstand second tubular members.

According to another aspect of the present invention, a method ofcoupling an expandable tubular member to a preexisting structure isprovided that includes positioning the expandable tubular member and anexpansion cone within the preexisting structure, anchoring theexpandable tubular member to the preexisting structure, and axiallydisplacing the expansion cone relative to the expandable tubular memberby pulling the expansion cone through the expandable tubular member. Theexpandable tubular member includes a plurality of tubular members havingthreaded portions that are coupled to one another by the process of:coating the threaded portions of the tubular members with a sealant,coupling the threaded portions of the tubular members and curing thesealant.

According to another aspect of the present invention, a method ofcoupling a tubular member to a preexisting structure is provided thatincludes positioning the tubular member and an expansion cone within thepreexisting structure, anchoring the tubular member to the preexistingstructure, and axially displacing the expansion cone relative to thetubular member by pulling the expansion cone through the expandabletubular member. The tubular member includes: a pair of rings forengaging the preexisting structure, and a sealing element positionedbetween the rings for sealing the interface between the tubular memberand the preexisting structure.

According to another aspect of the present invention, a method ofcoupling a tubular member to a preexisting structure is provided thatincludes positioning the expandable tubular member and an expansion conewithin the preexisting structure, anchoring the expandable tubularmember to the preexisting structure, and axially displacing theexpansion cone relative to the expandable tubular member by pulling theexpansion cone through the expandable tubular member. The tubular memberincludes one or more slots.

According to another aspect of the present invention, a method ofcoupling a tubular member to a preexisting structure is provided thatincludes positioning the expandable tubular member and an expansion conewithin the preexisting structure, anchoring the expandable tubularmember to the preexisting structure, and axially displacing theexpansion cone relative to the expandable tubular member by pulling theexpansion cone through the expandable tubular member. The tubular memberincludes: a first preexpanded portion, an intermediate portion coupledto the first preexpanded portion including a sealing element, and asecond preexpanded portion coupled to the intermediate portion.

According to another aspect of the present invention, a method ofcoupling a tubular member to a preexisting structure is provided thatincludes positioning the expandable tubular member and an expansion conewithin the preexisting structure, anchoring the expandable tubularmember to the preexisting structure, and axially displacing theexpansion cone relative to the expandable tubular member by pulling theexpansion cone through the expandable tubular member by applying anaxial force to the expansion cone. The axial force includes: asubstantially constant axial force, and an increased axial force.

According to another aspect of the present invention, a method ofcoupling a tubular member to a preexisting structure is provided thatincludes positioning the tubular member and an expansion cone within thepreexisting structure, anchoring the tubular member to the preexistingstructure, and axially displacing the expansion cone relative to theexpandable tubular member by pushing and pulling the expansion conethrough the expandable tubular member.

According to another aspect of the present invention, a method ofcoupling a tubular member to a preexisting structure is provided thatincludes positioning the tubular member and an expansion cone within thepreexisting structure, anchoring the tubular member to the preexistingstructure, axially displacing the expansion cone relative to the tubularmember by pulling the expansion cone through the expandable tubularmember, and injecting a curable fluidic sealing material between thetubular member and the preexisting structure prior to axially displacingthe expansion cone.

According to another aspect of the present invention, a method ofcoupling a tubular member to a preexisting structure is provided thatincludes

-   -   positioning the tubular member and an expansion cone within the        preexisting structure, anchoring the tubular member to the        preexisting structure by increasing the size of the expansion        cone, and axially displacing the expansion cone relative to the        tubular member by pulling the expansion cone through the tubular        member.

According to another aspect of the present invention, a method ofcoupling a tubular member to a preexisting structure is provided thatincludes positioning the tubular member and an expansion cone within thepreexisting structure, anchoring the tubular member to the preexistingstructure by heating a portion of the tubular member, and axiallydisplacing the expansion cone relative to the tubular member by pullingthe expansion cone through the tubular member.

According to another aspect of the present invention, a method ofcoupling an expandable tubular member to a preexisting structure isprovided that includes positioning the expandable tubular member, anexpansion cone, and an anchoring device within the preexistingstructure, positioning the anchoring device above the expansion cone,anchoring the expandable tubular member to the preexisting structureusing the anchoring device, and axially displacing the expansion cone.

According to another aspect of the present invention, a method ofcoupling an expandable tubular member to a preexisting structure isprovided that includes positioning the tubular member and an expansioncone within the preexisting structure, explosively anchoring the tubularmember to the preexisting structure, and axially displacing theexpansion cone relative to the tubular member.

According to another aspect of the present invention, a method ofcoupling an expandable tubular to a preexisting structure is providedthat includes fixing the position of an expansion cone within thepreexisting structure, driving the expandable tubular member onto theexpansion cone in a first direction, and axially displacing theexpansion cone in a second direction relative to the expandable tubularmember. The first and second directions are different.

According to another aspect of the present invention, a method ofcoupling an expandable tubular member to a preexisting structure isprovided that includes placing the expandable tubular, an expansioncone, and a resilient anchor within the preexisting structure, releasingthe resilient anchor, and axially displacing the expansion cone withinthe expandable tubular member.

According to another aspect of the present invention, a method ofcoupling an expandable tubular member to a preexisting structure isprovided that includes placing the expandable tubular member, anexpansion cone, and an anchor into the preexisting structure, andanchoring the expandable tubular member to the preexisting structure by:pivoting one or more engagement elements, and axially displacing theexpansion cone.

According to another aspect of the present invention, a method ofcoupling an expandable tubular member to a preexisting structure isprovided that includes placing the expandable tubular member and anexpansion cone into the preexisting structure, placing a quantity of afluidic material onto the expandable tubular member to anchor theexpandable tubular member to the preexisting structure, and axiallydisplacing the expansion cone.

According to another aspect of the present invention, a method ofcoupling an expandable tubular member to a preexisting structure isprovided that includes positioning the expandable tubular member and anexpansion cone into the preexisting structure, anchoring the expandabletubular member to the preexisting structure by injecting a quantity of ahardenable fluidic material into the preexisting structure, at leastpartially curing the hardenable fluidic sealing material, and axiallydisplacing the expansion cone.

According to another aspect of the present invention, a method ofcoupling an expandable tubular member to a preexisting structure isprovided that includes placing the expandable tubular member and anexpansion cone within the preexisting structure and applying an axialforce to the expandable tubular member in a downward direction.

According to another aspect of the present invention, a method ofcoupling an expandable tubular member to a preexisting structure isprovided that includes placing the expandable tubular member and anexpansion cone within the preexisting structure, injecting a quantity ofa first fluidic material having a first density into the region of thepreexisting structure outside of the expandable tubular member, andinjecting a quantity of a second fluidic material having a seconddensity into a portion of the expandable tubular member below theexpansion cone. The second density is greater than the first density.

According to another aspect of the present invention, a method ofcoupling an expandable tubular member to a preexisting structure isprovided that includes placing the expandable tubular member and anexpansion cone into the preexisting structure, anchoring the expandabletubular member to the preexisting structure, applying an axial force tothe expansion cone, and pressurizing an interior portion of theexpandable tubular member below the expansion cone.

According to another aspect of the present invention, a method ofcoupling an expandable tubular member to a preexisting structure isprovided that includes placing the expandable tubular member and anexpansion cone into the preexisting structure and applying an axialforce to the expandable tubular member.

According to another aspect of the present invention, an apparatus forcoupling a tubular member to a preexisting structure is provided thatincludes an expandable tubular member, an anchoring device adapted tocouple the expandable tubular member to the preexisting structure, andan expansion cone movably coupled to the expandable tubular member andadapted to radially expand the expandable tubular member, including: ahousing including a tapered first end and a second end, one or moregrooves formed in the outer surface of the tapered first end, and one ormore axial flow passages fluidicly coupled to the grooves.

According to another aspect of the present invention, an apparatus forcoupling an expandable tubular member to a preexisting structure isprovided that includes an expandable tubular member, an anchoring deviceadapted to couple the expandable tubular member to the preexistingstructure, and an expansion cone movably coupled to the expandabletubular member and adapted to radially expand the expandable tubularmember. The expandable tubular member includes: an annular member,having: a wall thickness that varies less than about 8%, a hoop yieldstrength that varies less than about 10%, imperfections of less thanabout 8% of the wall thickness, no failure for radial expansions of upto about 30%, and no necking of the walls of the annular member forradial expansions of up to about 25%.

According to another aspect of the present invention, an apparatus forcoupling an expandable tubular member to a preexisting structure isprovided that includes an expandable tubular member, an anchoring deviceadapted to couple the expandable tubular member to the preexistingstructure, and an expansion cone movably coupled to the expandabletubular member and adapted to radially expand the expandable tubularmember. The expandable tubular member includes: a first tubular member,a second tubular member, and a threaded connection for coupling thefirst tubular member to the second tubular member, the threadedconnection including: one or more sealing members for sealing theinterface between the first and second tubular members.

According to another aspect of the present invention, an apparatus forcoupling an expandable tubular member to a preexisting structure isprovided that includes an expandable tubular member, an anchoring deviceadapted to couple the expandable tubular member to the preexistingstructure, and an expansion cone movably coupled to the expandabletubular member and adapted to radially expand the expandable tubularmember. The expandable tubular member includes: a layer of a lubricantcoupled to the interior surface of the tubular member.

According to another aspect of the present invention, an apparatus forcoupling an expandable tubular member to a preexisting structure isprovided that includes an expandable tubular member, an anchoring deviceadapted to couple the expandable tubular member to the preexistingstructure, and an expansion cone movably coupled to the expandabletubular member and adapted to radially expand the expandable tubularmember. The expandable tubular member includes: a pair of tubularmembers having threaded portions coupled to one another, and a quantityof a sealant within the threaded portions of the tubular members.

According to another aspect of the present invention, an apparatus forcoupling an expandable tubular member to a preexisting structure isprovided that includes an expandable tubular member, an anchoring deviceadapted to couple the expandable tubular member to the preexistingstructure, and an expansion cone movably coupled to the expandabletubular member and adapted to radially expand the expandable tubularmember. The expandable tubular member includes: a pair of rings forengaging the preexisting structure, and a sealing element positionedbetween the rings for sealing the interface between the tubular memberand the preexisting structure.

According to another aspect of the present invention, an apparatus forcoupling an expandable tubular member to a preexisting structure isprovided that includes an expandable tubular member, an anchoring deviceadapted to couple the expandable tubular member to the preexistingstructure, and an expansion cone movably coupled to the expandabletubular member and adapted to radially expand the expandable tubularmember. The expandable tubular member includes one or more slots.

According to another aspect of the present invention, an apparatus forcoupling an expandable tubular member to a preexisting structure isprovided that includes an expandable tubular member, an anchoring deviceadapted to couple the expandable tubular member to the preexistingstructure, and an expansion cone movably coupled to the expandabletubular member and adapted to radially expand the expandable tubularmember. The expandable tubular member includes: a first preexpandedportion, an intermediate portion coupled to the first preexpandedportion including a sealing element, and a second preexpanded portioncoupled to the intermediate portion.

According to another aspect of the present invention, an apparatus forcoupling an expandable tubular member to a preexisting structure isprovided that includes an expandable tubular member, an anchoring deviceadapted to couple the expandable tubular member to the preexistingstructure, an expansion cone movably coupled to the expandable tubularmember and adapted to radially expand the expandable tubular member, anda valveable fluid passage coupled to the anchoring device.

According to another aspect of the present invention, an apparatus forcoupling an expandable tubular member to a preexisting structure isprovided that includes a first support member, a second support membercoupled to the first support member, an expansion cone coupled to thefirst support member, an expandable tubular member coupled to theexpansion cone, and an anchoring device coupled to the second supportmember adapted to couple the expandable tubular member to thepreexisting structure. The anchoring device is positioned above theexpansion cone.

According to another aspect of the present invention, an apparatus forcoupling an expandable tubular member to a preexisting structure isprovided that includes a first support member, a second support membercoupled to the first support member, an expansion cone coupled to thefirst support member, an expandable tubular member coupled to theexpansion cone, and an explosive anchoring device coupled to the secondsupport member adapted to couple the expandable tubular member to thepreexisting structure.

According to another aspect of the present invention, an apparatus forcoupling an expandable tubular member to a preexisting structure isprovided that includes a support member, an expandable expansion conecoupled to the support member, and an expandable tubular member coupledto the expansion cone.

According to another aspect of the present invention, an apparatus forcoupling an expandable tubular member to a preexisting structure isprovided that includes a support member, an expandable expansion conecoupled to the support member, and an expandable tubular member coupledto the expandable expansion cone.

According to another aspect of the present invention, an apparatus forcoupling an expandable tubular to a preexisting structure is providedthat includes a support member, an expansion cone coupled to the supportmember, an expandable tubular member coupled to the expansion coneincluding one or more shape memory metal inserts, and a heater coupledto the support member in opposing relation to the shape memory metalinserts.

According to another aspect of the present invention, an apparatus forcoupling an expandable tubular member to a preexisting structure isprovided that includes a support member, an expansion cone coupled tothe support member, an expandable tubular member coupled to theexpandable expansion cone, and a resilient anchor coupled to theexpandable tubular member.

According to another aspect of the present invention, an expandabletubular member is provided that includes: an expandable tubular body,one or more resilient panels coupled to the expandable tubular body, anda release member releasably coupled to the resilient panels adapted tocontrollably release the resilient panels.

According to another aspect of the present invention, an apparatus forcoupling an expandable tubular member to a preexisting structure isprovided that includes a support member, an expansion cone coupled tothe support member, an expandable tubular member coupled to theexpandable expansion cone, and an anchor coupled to the expandabletubular member, including: one or more spikes pivotally coupled to theexpandable tubular member for engaging the preexisting structure.

According to another aspect of the present invention, an apparatus forcoupling an expandable tubular member to a preexisting structure isprovided that includes a support member, an expansion cone coupled tothe support member, an expandable tubular member coupled to theexpandable expansion cone, and an anchor coupled to the expandabletubular member, including: one or more petal baskets pivotally coupledto the expandable tubular member.

According to another aspect of the present invention, an apparatus forcoupling an expandable tubular member to a preexisting structure isprovided that includes a support member, an expansion cone coupled tothe support member, an expandable tubular member coupled to theexpansion cone, including: a slotted portion provided at one end of theexpandable tubular member.

According to another aspect of the present invention, an apparatus forcoupling an expandable tubular member to a preexisting structure isprovided that includes a support member, an expansion cone, anexpandable tubular member coupled to the expansion cone, a couplingdevice coupled to the support member and an end portion of theexpandable tubular member, and

-   -   a mass coupled to the end portion of the expandable tubular        member. The weight of the mass is greater than the yield        strength of the expandable tubular member.

According to another aspect of the present invention, an apparatus forcoupling an expandable tubular member to a preexisting structure isprovided that includes a support member including a fluid passage, anexpansion cone coupled to the support member, an expandable tubularmember coupled to the expansion cone, a slip joint coupled to theexpansion cone, an end plate coupled to the slip joint, a fluid chambercoupled to the fluid passage, the fluid chamber defined by the interiorportion of the expandable tubular member between the expansion cone andthe end plate.

According to another aspect of the present invention, a method ofcoupling a tubular member to a preexisting structure is provided thatincludes positioning the tubular member and an expansion cone within thepreexisting structure, axially displacing the expansion cone, removingthe expansion cone, and applying direct radial pressure to the tubularmember.

According to another aspect of the present invention, an apparatus isprovided that includes a tubular member coupled to a preexistingstructure. The tubular member is coupled to the preexisting structure bythe process of:

-   -   positioning the tubular member and an expansion cone within the        preexisting structure, axially displacing the expansion cone,        removing the expansion cone, and applying direct radial pressure        to the tubular member.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 a is a fragmentary cross-sectional illustration of the placementof an embodiment of an apparatus for expanding a tubular member within awellbore casing.

FIG. 1 b is a fragmentary cross-sectional illustration of the apparatusof FIG. 1 a after anchoring the expandable tubular member of theapparatus to the wellbore casing.

FIG. 1 c is a fragmentary cross-sectional illustration of the apparatusof FIG. 1 b after initiating the axial displacement of the expansioncone.

FIG. 1 d is a fragmentary cross-sectional illustration of the apparatusof FIG. 1 b after initiating the axial displacement of the expansioncone by pulling on the expansion cone and injecting a pressurized fluidbelow the expansion cone.

FIG. 1 e is a fragmentary cross-sectional illustration of the apparatusof FIGS. 1 c and 1 d after the completion of the radial expansion of theexpandable tubular member.

FIG. 1 f is a fragmentary cross-sectional illustration of the apparatusof FIG. 1 e after the decoupling of the anchoring device of theapparatus from the wellbore casing.

FIG. 1 g is a fragmentary cross-sectional illustration of the apparatusof FIG. 1 f after the removal of the anchoring device of the apparatusfrom the wellbore casing.

FIG. 2 a is a fragmentary cross-sectional illustration of the placementof an embodiment of an apparatus for expanding a tubular member within awellbore casing and an open hole in a subterranean formation.

FIG. 2 b is a fragmentary cross-sectional illustration of the apparatusof FIG. 2 a after anchoring the expandable tubular member of theapparatus to the open hole.

FIG. 2 c is a fragmentary cross-sectional illustration of the apparatusof FIG. 2 b after initiating the axial displacement of the expansioncone.

FIG. 2 d is a fragmentary cross-sectional illustration of the apparatusof FIG. 2 b after initiating the axial displacement of the expansioncone by pulling on the expansion cone and also by injecting apressurized fluid below the expansion cone.

FIG. 2 e is a fragmentary cross-sectional illustration of the apparatusof FIGS. 2 c and 2 d after the completion of the radial expansion of theexpandable tubular member.

FIG. 2 f is a fragmentary cross-sectional illustration of the apparatusof FIG. 2 e after the decoupling of the anchoring device of theapparatus from the open hole.

FIG. 3 a is a fragmentary cross-sectional illustration of the placementof an embodiment of an apparatus for expanding a tubular member within awellbore casing.

FIG. 3 b is a fragmentary cross-sectional illustration of the apparatusof FIG. 3 a after anchoring the expandable tubular member of theapparatus to the wellbore casing.

FIG. 3 c is a fragmentary cross-sectional illustration of the apparatusof FIG. 3 b after initiating the axial displacement of the expansioncone.

FIG. 3 d is a fragmentary cross-sectional illustration of the apparatusof FIG. 3 c after completing the radial expansion of the expandabletubular member.

FIG. 4 is a fragmentary cross-sectional illustration of an embodiment ofa shock absorbing system for use in the apparatus of FIGS. 1 a to 3 d.

FIG. 5 is a cross-sectional illustration of an embodiment of a couplingarrangement for use in the expandable tubular members of the apparatusof FIGS. 1 a to 3 d.

FIG. 6 is a cross-sectional illustration of an embodiment of anexpandable tubular member having a slotted lower section for use in theapparatus of FIGS. 1 a to 3 d.

FIG. 7 is a cross-sectional illustration of an embodiment of anexpandable tubular member having a pre-expanded upper portion for use inthe apparatus of FIGS. 1 a to 3 d.

FIG. 8 is a cross-sectional illustration of an embodiment of anexpandable tubular member having a slotted upper section for use in theapparatus of FIGS. 1 a to 3 d.

FIG. 9 is a graphical illustration of an embodiment of a method ofapplying an axial force to the expansion cones of the apparatus of FIGS.1 a to 3 d.

FIG. 10 a is a fragmentary cross-sectional illustration of the placementof an embodiment of an apparatus for expanding a tubular member within awellbore casing.

FIG. 10 b is a fragmentary cross-sectional illustration of the apparatusof FIG. 10 a during the injection of a non-hardenable fluidic materialinto and out of the apparatus.

FIG. 10 c is a fragmentary cross-sectional illustration of the apparatusof FIG. 10 b during the injection of a hardenable fluidic sealingmaterial into and out of the apparatus.

FIG. 10 d is a fragmentary cross-sectional illustration of the apparatusof FIG. 10 c after the placement of a valve closure element into thevalve passage of the anchoring device of the apparatus.

FIG. 10 e is a fragmentary cross-sectional illustration of the apparatusof FIG. 10 d after anchoring the expandable tubular member of theapparatus to the wellbore casing.

FIG. 10 f is a fragmentary cross-sectional illustration of the apparatusof FIG. 10 e after initiating the axial displacement of the expansioncone.

FIG. 10 g is a fragmentary cross-sectional illustration of the apparatusof FIG. 10 e after initiating the axial displacement of the expansioncone by pulling on the expansion cone and injecting a pressurized fluidbelow the expansion cone.

FIG. 10 h is a fragmentary cross-sectional illustration of the apparatusof FIGS. 10 f and 10 g after the completion of the radial expansion ofthe expandable tubular member.

FIG. 10 i is a fragmentary cross-sectional illustration of the apparatusof FIG. 10 h after the decoupling and removal of the anchoring device ofthe apparatus from the wellbore casing.

FIG. 11 a is a fragmentary cross-sectional illustration of analternative embodiment of an apparatus for coupling an expandabletubular member to a preexisting structure.

FIG. 11 b is a fragmentary cross-sectional illustration of the apparatusof FIG. 11 a after anchoring the expandable tubular member of theapparatus to the wellbore casing.

FIG. 11 c is a fragmentary cross-sectional illustration of the apparatusof FIG. 11 b after initiating the axial displacement of the expansioncone.

FIG. 11 d is a fragmentary cross-sectional illustration of the apparatusof FIG. 11 c after stopping the axial displacement of the expansion coneprior to deactivating the anchoring device.

FIG. 11 e is a fragmentary cross-sectional illustration of the apparatusof FIG. 11 d after deactivating the anchoring device.

FIG. 11 f is a fragmentary cross-sectional illustration of the apparatusof FIG. 11 e after initiating the axial displacement of the expansioncone and the deactivated anchoring device.

FIG. 11 g is a fragmentary cross-sectional illustration of the apparatusof FIG. 11 f after the completion of the radial expansion of theexpandable tubular member.

FIG. 12 a is a fragmentary cross-sectional illustration of analternative embodiment of an apparatus for coupling an expandabletubular member to a preexisting structure positioned within a wellbore.

FIG. 12 b is a fragmentary cross-sectional illustration of the apparatusof FIG. 12 a after expanding the expandable expansion cone in order toanchor the expandable tubular member to the wellbore casing.

FIG. 12 c is a fragmentary cross-sectional illustration of the apparatusof FIG. 12 b after initiating the axial displacement of the expandableexpansion cone.

FIG. 12 d is a fragmentary cross-sectional illustration of the apparatusof FIG. 12 c after completing the radial expansion of the expandabletubular member.

FIG. 13 a is a fragmentary cross-sectional illustration of analternative embodiment of an apparatus for coupling an expandabletubular member to a preexisting structure positioned within a wellbore.

FIG. 13 b is a fragmentary cross-sectional illustration of the apparatusof FIG. 13 a after activating the shape memory metal inserts in order toanchor the expandable tubular member to the wellbore casing.

FIG. 13 c is a fragmentary cross-sectional illustration of the apparatusof FIG. 13 b after initiating the axial displacement of the expansioncone.

FIG. 13 d is a fragmentary cross-sectional illustration of the apparatusof FIG. 13 c after completing the radial expansion of the expandabletubular member.

FIG. 14 a is a fragmentary cross-sectional illustration of analternative embodiment of an apparatus for coupling an expandabletubular member to a preexisting structure positioned within a wellborecasing.

FIG. 14 b is a fragmentary cross-sectional illustration of the apparatusof FIG. 14 a after coupling the packer to the wellbore casing.

FIG. 14 c is a fragmentary cross-sectional illustration of the apparatusof FIG. 14 b after initiating the axial displacement of the expandabletubular member towards the expansion cone.

FIG. 14 d is a fragmentary cross-sectional illustration of the apparatusof FIG. 14 c after radially expanding the end of the expandable tubularmember onto the expansion cone.

FIG. 14 e is a fragmentary cross-sectional illustration of the apparatusof FIG. 14 d after decoupling the packer from the wellbore casing.

FIG. 14 f is a fragmentary cross-sectional illustration of the apparatusof FIG. 14 e after initiating the axial displacement of the expansioncone relative to the expandable tubular member.

FIG. 14 g is a fragmentary cross-sectional illustration of thecompletion of the radial expansion of the expandable tubular member.

FIG. 15 a is a fragmentary cross-sectional illustration of analternative embodiment of an apparatus for coupling an expandabletubular member to a preexisting structure positioned within a wellbore.

FIG. 15 b is a fragmentary cross-sectional illustration of the apparatusof FIG. 15 a after coupling the resilient anchor to the wellbore casing.

FIG. 15 c is a fragmentary cross-sectional illustration of the apparatusof FIG. 15 b after initiating the axial displacement of the expansioncone.

FIG. 15 d is a fragmentary cross-sectional illustration of the apparatusof FIG. 15 c after completion of the radial expansion of the expandabletubular member.

FIG. 16 a is a top view of an embodiment of a resilient anchor for usein the apparatus of FIG. 15 a.

FIG. 16 b is a top view of the resilient anchor of FIG. 16 a afterreleasing the coiled resilient member.

FIG. 17 a is a top view of an alternate embodiment of a resilient anchorfor use in the apparatus of FIG. 15 a.

FIG. 17 b is a top view of the resilient anchor of FIG. 17 a afterreleasing the resilient elements.

FIG. 18 a is a fragmentary cross-sectional top view of an alternateembodiment of a resilient anchor for use in the apparatus of FIG. 15 a.

FIG. 18 b is a fragmentary cross-sectional top view of the resilientanchor of FIG. 18 a after releasing the resilient elements.

FIG. 19 a is an front view of an embodiment of an expandable tubularmember including one or more resilient panels.

FIG. 19 b is a cross-sectional view of the expandable tubular member ofFIG. 19 a.

FIG. 19 c is a bottom view of the expandable tubular member of FIG. 19a.

FIG. 20 a is a fragmentary cross-sectional illustration of analternative embodiment of an apparatus for coupling an expandabletubular member to a preexisting structure positioned within a wellbore.

FIG. 20 b is a fragmentary cross-sectional illustration of the apparatusof FIG. 20 a after coupling the anchor to the wellbore casing.

FIG. 20 c is a fragmentary cross-sectional illustration of the apparatusof FIG. 20 b after initiating the axial displacement of the expansioncone.

FIG. 20 d is a fragmentary cross-sectional illustration of the apparatusof FIG. 20 c after completion of the radial expansion of the expandabletubular member.

FIG. 21 a is an illustration of an embodiment of the anchor of theapparatus of FIG. 20 a.

FIG. 21 b is an illustration of the anchor of FIG. 21 a after outwardlyextending the spikes.

FIG. 22 a is an illustration of an alternative embodiment of the anchorof the apparatus of FIG. 20 a.

FIG. 22 b is an illustration of the anchor of FIG. 22 a after outwardlyextending the spikes.

FIG. 22 c is a cross-sectional illustration of the petals of the anchorof FIG. 22 a.

FIG. 23 a is a fragmentary cross-sectional illustration of analternative embodiment of an apparatus for coupling an expandabletubular member to a preexisting structure positioned within a wellbore.

FIG. 23 b is a fragmentary cross-sectional illustration of the apparatusof FIG. 20 a after injecting a quantity of a hardenable fluidic sealingmaterial into the open hole wellbore section proximate the lower sectionof the expandable tubular member.

FIG. 23 c is a fragmentary cross-sectional illustration of the apparatusof FIG. 23 b after permitting the hardenable fluidic sealing material toat least partially cure.

FIG. 23 d is a fragmentary cross-sectional illustration of the apparatusof FIG. 23 c after initiating the axial displacement of the expansioncone.

FIG. 23 e is a fragmentary cross-sectional illustration of the apparatusof FIG. 23 d after completion of the radial expansion of the expandabletubular member.

FIG. 24 a is a fragmentary cross-sectional illustration of analternative embodiment of an apparatus and method for coupling anexpandable tubular member to a preexisting structure positioned within awellbore casing and an open hole wellbore section.

FIG. 24 b is a fragmentary cross-sectional illustration of the apparatusof FIG. 24 a after releasing the packer.

FIG. 24 c is a fragmentary cross-sectional illustration of the apparatusof FIG. 24 b after extruding the expandable tubular member off of theexpansion cone.

FIG. 25 a is a fragmentary cross-sectional illustration of analternative embodiment of an apparatus and method for coupling anexpandable tubular member to a preexisting structure positioned within awellbore casing and an open hole wellbore section.

FIG. 25 b is a fragmentary cross-sectional illustration of the apparatusof FIG. 25 a after injecting a quantity of a fluidic material into theexpandable tubular member having a higher density than the fluid withinthe preexisting structure outside of the expandable tubular member.

FIG. 25 c is a fragmentary cross-sectional illustration of the apparatusof FIG. 25 b after extruding the expandable tubular member off of theexpansion cone.

FIG. 26 a is a fragmentary cross-sectional illustration of analternative embodiment of an apparatus and method for coupling anexpandable tubular member to a preexisting structure.

FIG. 26 b is a fragmentary cross-sectional illustration of the apparatusof FIG. 26 a after the initiation of the radial expansion process.

FIG. 26 c is a fragmentary cross-sectional illustration of thecompletion of the radial expansion process using the apparatus of FIG.26 b.

FIG. 27 is a flow chart illustration of an exemplary embodiment of amethod of coupling an expandable tubular to a preexisting structure.

FIG. 28 is a cross-sectional illustration of an expandable tubularcoupled to a preexisting structure using an expansion cone.

FIG. 29 is a cross-sectional illustration of the subsequent applicationof radial pressure to the expandable tubular member of FIG. 28.

DETAILED DESCRIPTION

A method and apparatus for coupling tubular members to a preexistingstructure is provided. In an exemplary embodiment, the tubular membersare coupled to the preexisting structure by radially expanding thetubular members into contact with the preexisting structure. In anexemplary embodiment, the tubular members are radially expanded byanchoring one end of the tubular members to the preexisting structureand then pulling an expansion cone through the tubular members. In thismanner, the tubular members are radially expanded and coupled to thepreexisting structure.

Referring initially to FIGS, 1 a, 1 b, 1 c, 1 d, 1 e, 1 f and 1 g, anexemplary embodiment of a method and apparatus for coupling anexpandable tubular member to a preexisting structure will be described.Referring to FIG. 1 a, a wellbore casing 100 is positioned within asubterranean formation 105. The wellbore casing 100 may be positioned inany orientation from the vertical direction to the horizontal direction.The wellbore casing 100 further includes one or more openings 110 thatmay have been the result of unintentional damage to the wellbore casing100, or due to a prior perforation or fracturing operation performedupon the surrounding subterranean formation 105. As will be recognizedby persons having ordinary skill in the art, the openings 110 canadversely affect the subsequent operation and use of the wellbore casing100 unless they are sealed off.

In an exemplary embodiment, an apparatus 115 is utilized to seal off theopenings 110 in the wellbore casing 100. More generally, the apparatus115 is preferably utilized to form or repair wellbore casings,pipelines, or structural supports.

The apparatus 115 preferably includes a first support member 120, asecond support member 125, an expansion cone 130, an anchoring device135, and expandable tubular member 140, and one or more sealing members145.

The first support member 120 is preferably adapted to be coupled to asurface location. The first support member 120 is further coupled to theanchoring device 135. The first support member 120 is preferably adaptedto convey pressurized fluidic materials and/or electrical current and/orcommunication signals from a surface location to the anchoring device135. The first support member 120 may, for example, be conventionalcommercially available slick wire, braided wire, coiled tubing, ordrilling stock material.

The second support member 125 is preferably adapted to be coupled to asurface location. The second support member 125 is further coupled tothe expansion cone 130. The second support member 125 is preferablyadapted to permit the expansion cone 130 to be axially displacedrelative to the first support member 120. The second support member 125may, for example, be conventional commercially available slick wire,braided wire, coiled tubing, or drilling stock material.

The expansion cone 130 is coupled to the second support member 125. Theexpansion cone 130 is preferably adapted to radially expand theexpandable tubular member 140 when the expansion cone 130 is axiallydisplaced relative to the expandable tubular member 140. In an exemplaryembodiment, the expansion cone 130 is provided substantially asdisclosed in one or more of the following: (1) U.S. utility patentapplication Ser. No. 09/454,139, attorney docket no. 25791.3.02, filedon Dec. 3, 1999, which claimed the benefit of the filing date of U.S.provisional patent application No. 60/111,293, attorney docket no.25791.3, filed on Dec. 7, 1998; (2) U.S. utility patent application Ser.No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/121,702, filed on Feb. 25, 1999; (3) U.S. utilitypatent application Ser. No. 09/502,350, attorney docket no. 25791.8.02,filed on Feb. 10, 2000, which claimed the benefit of the filing date ofU.S. provisional application No. 60/119,611, attorney docket no.25791.8; (4) U.S. utility patent application Ser. No. 09/440,338,attorney docket no. 25791.9.02, filed on Nov. 15, 1999, which claimedthe benefit of the filing date of U.S. provisional application No.60/108,558, attorney docket no. 25791.9, filed on Nov. 16, 1998; (5)U.S. provisional patent application No. 60/183,546, filed on Feb. 18,2000; (6) U.S. utility patent application Ser. No. 09/523,460, attorneydocket no. 25791.11.02, filed on Mar. 10, 2000, which claimed thebenefit of the filing date of U.S. provisional application No.60/124,042, filed on Mar. 11, 1999; (7) U.S. utility patent applicationSer. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24,2000, which claimed the benefit of the filing dates of U.S. provisionalapplication No. 60/121,841, attorney docket no. 25791.12, filed on Feb.26, 1999 and U.S. provisional application No. 60/154,047, attorneydocket no. 25791.29, filed on Sep. 16, 1999; (8) U.S. utilityapplication Ser. No. 09/511,941, attorney docket no. 25791.16.02, filedon Feb. 24, 2000, which claimed the benefit of the filing date of U.S.provisional Ser. No. 60/121,907, attorney docket no. 25791.16, filed onFeb. 26, 1999; (9) U.S. utility patent application Ser. No. 09/588,946,attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claimedthe benefit of the filing date of U.S. provisional patent applicationSer. No. 60/137,998, attorney docket no. 25791.17, filed on Jun. 7,1999; (10) U.S. utility patent application Ser. No. 09/559,122, attorneydocket no. 25791.23.02, filed on Apr. 26, 2000, which claimed thebenefit of the filing date of U.S. provisional application No.60/131,106, attorney docket no. 25791.23, filed on Apr. 26, 1999; (11)U.S. provisional application No. 60/146,203, attorney docket no.25791.25, filed on Jul. 29, 1999; (12) U.S. provisional application No.60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999; (13)U.S. provisional patent application Ser. No. 60/162,671, attorney docketno. 25791.27, filed on Nov. 1, 1999; (14) U.S. provisional applicationNo. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999;(15) U.S. provisional patent application No. 60/159,033, attorney docketno. 25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patentapplication No. 60/165,228, attorney docket no. 25791.39, filed on Nov.12, 1999, the disclosures of which are incorporated herein by reference.

The anchoring device 135 is coupled to the first support member 120. Theanchoring device 135 is preferably adapted to be controllably coupled tothe expandable tubular member 140 and the wellbore casing 100. In thismanner, the anchoring device 135 preferably controllably anchors theexpandable tubular member 140 to the wellbore casing 100 to facilitatethe radial expansion of the expandable tubular member 140 by the axialdisplacement of the expansion cone 130. In an exemplary embodiment, theanchoring device 135 includes one or more expandable elements 150 thatare adapted to controllably extend from the body of the anchoring device135 to engage both the expandable tubular member 140 and the wellborecasing 100. In an exemplary embodiment, the expandable elements 150 areactuated using fluidic pressure. In an exemplary embodiment, theanchoring device 135 is any one of the hydraulically actuated packerscommercially available from Halliburton Energy Services or Baker-Hughes.

The expandable tubular member 140 is removably coupled to the expansioncone 130. The expandable tubular member 140 is further preferablyadapted to be removably coupled to the expandable element 150 of theanchoring device 135. In an exemplary embodiment, the expandable tubularmember 140 includes one or more anchoring windows 155 for permitting theexpandable elements 150 of the anchoring device 135 to engage thewellbore casing 100 and the expandable tubular member 140.

In an exemplary embodiment, the expandable tubular member 140 furtherincludes a lower section 160, an intermediate section 165, and an uppersection 170. In an exemplary embodiment, the lower section 160 includesthe anchoring windows 155 in order to provide anchoring at an endportion of the expandable tubular member 140. In an exemplaryembodiment, the wall thickness of the lower and intermediate sections,160 and 165, are less than the wall thickness of the upper section 170in order to optimally couple the radially expanded portion of theexpandable tubular member 140 to the wellbore casing 100.

In an exemplary embodiment, the expandable tubular member 140 is furtherprovided substantially as disclosed in one or more of the following: (1)U.S. utility patent application Ser. No. 09/454,139, attorney docket no.25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of thefiling date of U.S. provisional patent application No. 60/111,293,attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utilitypatent application Ser. No. 09/510,913, attorney docket no. 25791.7.02,filed on Feb. 23, 2000, which claimed the benefit of the filing date ofU.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3)U.S. utility patent application Ser. No. 09/502,350, attorney docket no.25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of thefiling date of U.S. provisional application No. 60/119,611, attorneydocket no. 25791.8; (4) U.S. utility patent application Ser. No.09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/108,558, attorney docket no. 25791.9, filed on Nov.16, 1998; (5) U.S. provisional patent application No. 60/183,546, filedon Feb. 18, 2000; (6) U.S. utility patent application Ser. No.09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utilitypatent application Ser. No. 09/512,895, attorney docket no. 25791.12.02,filed on Feb. 24, 2000, which claimed the benefit of the filing dates ofU.S. provisional application No. 60/121,841, attorney docket no.25791.12, filed on Feb. 26, 1999 and U.S. provisional application No.60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8)U.S. utility application Ser. No. 09/511,941, attorney docket no.25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of thefiling date of U.S. provisional serial No. 60/121,907, attorney docketno. 25791.16, filed on Feb. 26, 1999; (9) U.S. utility patentapplication Ser. No. 09/588,946, attorney docket no. 25791.17.02, filedon Jun. 7, 2000, which claimed the benefit of the filing date of U.S.provisional patent application Ser. No. 60/137,998, attorney docket no.25791.17, filed on Jun. 7, 1999; (10) U.S. utility patent applicationSer. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26,2000, which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/131,106, attorney docket no. 25791.23, filed on Apr.26, 1999; (11) U.S. provisional application No. 60/146,203, attorneydocket no. 25791.25, filed on Jul. 29, 1999; (12) U.S. provisionalapplication No. 60/143,039, attorney docket no. 25791.26, filed on Jul.9, 1999; (13) U.S. provisional patent application Ser. No. 60/162,671,attorney docket no. 25791.27, filed on Nov. 1, 1999; (14) U.S.provisional application No. 60/159,039, attorney docket no. 25791.36,filed on Oct. 12, 1999; (15) U.S. provisional patent application No.60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999; and(16) U.S. provisional patent application No. 60/165,228, attorney docketno. 25791.39, filed on Nov. 12, 1999, the disclosures of which areincorporated herein by reference.

The sealing members 145 are coupled to the outer surface of the upperportion 170 of the expandable tubular member 140. The sealing members145 are preferably adapted to engage and fluidicly seal the interfacebetween the radially expanded expandable tubular member 140 and thewellbore casing 100. In an exemplary embodiment, the apparatus 115includes a plurality of sealing members 145. In an exemplary embodiment,the sealing members 145 surround and isolate the opening 110.

As illustrated in FIG. 1 a, the apparatus 115 is preferably positionedwithin the wellbore casing 100 with the expandable tubular member 140positioned in opposing relation to the opening 110. In an exemplaryembodiment, the apparatus 115 includes a plurality of sealing members145 that are positioned above and below the opening 110. In this manner,the radial expansion of the expandable tubular member 140 optimallyfluidicly isolates the opening 110.

As illustrated in FIG. 1 b, the apparatus 115 is then anchored to thewellbore casing 100 using the anchoring device 135. In an exemplaryembodiment, the anchoring device 135 is pressurized and the expandableelement 150 is extended from the anchoring device 135 through thecorresponding anchoring window 155 in the expandable tubular member 140into intimate contact with the wellbore casing 100. In this manner, thelower section 160 of the expandable tubular member 140 is removablycoupled to the wellbore casing 100.

In an alternative embodiment, a compressible cement and/or epoxy is theninjected into the annular space between the unexpanded portion of thetubular member 140 and the wellbore casing 100. The compressible cementand/or epoxy is then permitted to at least partially cure prior to theinitiation of the radial expansion process. In this manner, an annularstructural support and fluidic seal is provided around the tubularmember 140.

As illustrated in FIG. 1 c, the expansion cone 130 is then axiallydisplaced by applying an axial force to the second support member 125.In an exemplary embodiment, the axial displacement of the expansion cone130 radially expands the expandable tubular member 140 into intimatecontact with the walls of the wellbore casing 100.

In an alternative embodiment, as illustrated in FIG. 1 d, the axialdisplacement of the expansion cone 130 is enhanced by injecting apressurized fluidic material into the annular space between the firstsupport member 120 and the second support member 125. In this manner, anupward axial force is applied to the lower annular face of the expansioncone 130 using the pressurized fluidic material. In this manner, atemporary need for increased axial force during the radial expansionprocess can be easily satisfied.

As illustrated in FIGS. 1 e, 1 f, and 1 g, after the expandable tubularmember 140 has been radially expanded by the axial displacement of theexpansion cone 130, the first support member 120 and the anchoringdevice 135 are preferably removed from expandable tubular member 140 byde-pressurizing the anchoring device 135 and then lifting the firstsupport member 120 and anchoring device 135 from the wellbore casing100.

As illustrated in FIG. 1 g, in an exemplary embodiment, the opening 110in the wellbore casing 100 is sealed off by the radially expandedtubular member 140. In this manner, repairs to the wellbore casing 100are optimally provided. More generally, the apparatus 115 is used torepair or form wellbore casings, pipelines, and structural supports.

Referring to FIGS, 2 a, 2 b, 2 c, 2 d, 2 e and 2 f, an alternativeembodiment of a method and apparatus for coupling an expandable tubularmember to a preexisting structure will be described. Referring to FIG. 2a, a wellbore casing 200 and an open hole wellbore section 205 arepositioned within a subterranean formation 210. The wellbore casing 200and the open hole wellbore section 205 may be positioned in anyorientation from the vertical direction to the horizontal direction.

In an exemplary embodiment, an apparatus 215 is utilized to couple anexpandable tubular member to an end portion of the wellbore casing 200.In this manner, the open hole wellbore section 205 is provided with acased portion. More generally, the apparatus 215 is preferably utilizedto form or repair wellbore casings, pipelines, or structural supports.

The apparatus 215 preferably includes a first support member 220, asecond support member 225, an expansion cone 230, an anchoring device235, an expandable tubular member 240, one or more upper sealing members245, one or more lower sealing members 250, and a flexible couplingelement 255.

The first support member 220 is preferably adapted to be coupled to asurface location. The first support member 220 is further coupled to theanchoring device 235. The first support member 220 is preferably adaptedto convey pressurized fluidic materials and/or electrical current and/orcommunication signals from a surface location to the anchoring device235. The first support member 220 may, for example, be conventionalcommercially available slick wire, braided wire, coiled tubing, ordrilling stock material.

The second support member 225 is preferably adapted to be coupled to asurface location. The second support member 225 is further coupled tothe expansion cone 230. The second support member 225 is preferablyadapted to permit the expansion cone 230 to be axially displacedrelative to the first support member 220. The second support member 225may, for example, be conventional commercially available slick wire,braided wire, coiled tubing, or drilling stock material.

In an alternative embodiment, the support member 220 is telescopicallycoupled to the support member 225, and the support member 225 is coupledto a surface support structure.

The expansion cone 230 is coupled to the second support member 225. Theexpansion cone 230 is preferably adapted to radially expand theexpandable tubular member 240 when the expansion cone 230 is axiallydisplaced relative to the expandable tubular member 240. In an exemplaryembodiment, the expansion cone 230 is provided substantially asdisclosed in one or more of the following: (1) U.S. utility patentapplication Ser. No. 09/454,139, attorney docket no. 25791.3.02, filedon Dec. 3, 1999, which claimed the benefit of the filing date of U.S.provisional patent application No. 60/111,293, attorney docket no.25791.3, filed on Dec. 7, 1998; (2) U.S. utility patent application Ser.No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000,which claimed the benefit of the filing date of U.S. provisional

The anchoring device 235 is coupled to the first support member 220. Theanchoring device 235 is preferably adapted to be controllably coupled tothe expandable tubular member 240 and the open hole wellbore section205. In this manner, the anchoring device 235 preferably controllablyanchors the expandable tubular member 240 to the open hole wellboresection 205 to facilitate the radial expansion of the expandable tubularmember 240 by the axial displacement of the expansion cone 230. In anexemplary embodiment, the anchoring device 235 includes one or moreexpandable elements 260 that are adapted to controllably extend from thebody of the anchoring device 235 to engage both the flexible couplingelement 255 and the open hole wellbore section 205. In an exemplaryembodiment, the expandable elements 260 are actuated using fluidicpressure. In an exemplary embodiment, the anchoring device 235 is anyone of the hydraulically actuated packers commercially available fromHalliburton Energy Services or Baker-Hughes.

The expandable tubular member 240 is removably coupled to the expansioncone 230. The expandable tubular member 240 is further preferablycoupled to the flexible coupling element 255.

In an exemplary embodiment, the expandable tubular member 240 furtherincludes a lower section 265, an intermediate section 270, and an uppersection 275. In an exemplary embodiment, the lower section 265 iscoupled to the flexible coupling element 255 in order to provideanchoring at an end portion of the expandable tubular member 240. In anexemplary embodiment, the wall thickness of the lower and intermediatesections, 265 and 270, are less than the wall thickness of the uppersection 275 in order to optimally couple the radially expanded portionof the expandable tubular member 240 to the wellbore casing 200 and theopen hole wellbore section 205.

In an exemplary embodiment, the expandable tubular member 240 is furtherprovided substantially as disclosed in one or more of the following: (1)U.S. utility patent application Ser. No. 09/454,139, attorney docket no.25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of thefiling date of U.S. provisional patent application No. 60/111,293,attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utilitypatent application Ser. No. 09/510,913, attorney docket no. 25791.7.02,filed on Feb. 23, 2000, which claimed the benefit of the filing date ofU.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3)U.S. utility patent application Ser. No. 09/502,350, attorney docket no.25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of thefiling date of U.S. provisional application No. 60/119,611, attorneydocket no. 25791.8; (4) U.S. utility patent application Ser. No.09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/108,558, attorney docket no. 25791.9, filed on Nov.16, 1998; (5) U.S. provisional patent application No. 60/183,546, filedon Feb. 18, 2000; (6) U.S. utility patent application Ser. No.09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utilitypatent application Ser. No. 09/512,895, attorney docket no. 25791.12.02,filed on Feb. 24, 2000, which claimed the benefit of the filing dates ofU.S. provisional application No. 60/121,841, attorney docket no.25791.12, filed on Feb. 26, 1999 and U.S. provisional application No.60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8)U.S. utility application Ser. No. 09/511,941, attorney docket no.25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of thefiling date of U.S. provisional Ser. No. 60/121,907, attorney docket no.25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent applicationSer. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7,2000, which claimed the benefit of the filing date of U.S. provisionalpatent application Ser. No. 60/137,998, attorney docket no. 25791.17,filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No.09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/131,106, attorney docket no. 25791.23, filed on Apr.26, 1999; (11) U.S. provisional application No. 60/146,203, attorneydocket no. 25791.25, filed on Jul. 29, 1999; (12) U.S. provisionalapplication No. 60/143,039, attorney docket no. 25791.26, filed on Jul.9, 1999; (13) U.S. provisional patent application Ser. No. 60/162,671,attorney docket no. 25791.27, filed on Nov. 1, 1999; (14) U.S.provisional application No. 60/159,039, attorney docket no. 25791.36,filed on Oct. 12, 1999; (15) U.S. provisional patent application No.60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999; and(16) U.S. provisional patent application No. 60/165,228, attorney docketno. 25791.39, filed on Nov. 12, 1999, the disclosures of which areincorporated herein by reference. application No. 60/121,702, filed onFeb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350,attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimedthe benefit of the filing date of U.S. provisional application No.60/119,611, attorney docket no. 25791.8; (4) U.S. utility patentapplication Ser. No. 09/440,338, attorney docket no. 25791.9.02, filedon Nov. 15, 1999, which claimed the benefit of the filing date of U.S.provisional application No. 60/108,558, attorney docket no. 25791.9,filed on Nov. 16, 1998; (5) U.S. provisional patent application No.60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent applicationSer. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10,2000, which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utilitypatent application Ser. No. 09/512,895, attorney docket no. 25791.12.02,filed on Feb. 24, 2000, which claimed the benefit of the filing dates ofU.S. provisional application No. 60/121,841, attorney docket no.25791.12, filed on Feb. 26, 1999 and U.S. provisional application No.60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8)U.S. utility application Ser. No. 09/511,941, attorney docket no.25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of thefiling date of U.S. provisional Ser. No. 60/121,907, attorney docket no.25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent applicationSer. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7,2000, which claimed the benefit of the filing date of U.S. provisionalpatent application Ser. No. 60/137,998, attorney docket no. 25791.17,filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No.09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/131,106, attorney docket no. 25791.23, filed on Apr.26, 1999; (11) U.S. provisional application No. 60/146,203, attorneydocket no. 25791.25, filed on Jul. 29, 1999; (12) U.S. provisionalapplication No. 60/143,039, attorney docket no. 25791.26, filed on Jul.9, 1999; (13) U.S. provisional patent application Ser. No. 60/162,671,attorney docket no. 25791.27, filed on Nov. 1, 1999; (14) U.S.provisional application No. 60/159,039, attorney docket no. 25791.36,filed on Oct. 12, 1999; (15) U.S. provisional patent application No.60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999; and(16) U.S. provisional patent application No. 60/165,228, attorney docketno. 25791.39, filed on Nov. 12, 1999, the disclosures of which areincorporated herein by reference.

The upper sealing members 245 are coupled to the outer surface of theupper portion 275 of the expandable tubular member 240. The uppersealing members 245 are preferably adapted to engage and fluidicly sealthe interface between the radially expanded expandable tubular member240 and the wellbore casing 200. In an exemplary embodiment, theapparatus 215 includes a plurality of upper sealing members 245.

The lower sealing members 250 are coupled to the outer surface of theupper portion 275 of the expandable tubular member 240. The lowersealing members 250 are preferably adapted to engage and fluidicly sealthe interface between the radially expanded expandable tubular member240 and the open wellbore section 205. In an exemplary embodiment, theapparatus 215 includes a plurality of lower sealing members 250.

The flexible coupling element 255 is coupled to the lower portion 265 ofthe expandable tubular member 240. The flexible coupling element 255 ispreferably adapted to radially expanded by the anchoring device 235 intoengagement within the walls of the open hole wellbore section 205. Inthis manner, the lower portion 265 of the expandable tubular member 240is coupled to the walls of the open hole wellbore section 205. In anexemplary embodiment, the flexible coupling element 255 is a slottedtubular member. In an exemplary embodiment, the flexible couplingelement 255 includes one or more hook elements for engaging the walls ofthe open hole wellbore section 205.

As illustrated in FIG. 2 a, the apparatus 215 is preferably positionedwith the expandable tubular member 240 positioned in overlappingrelation with a portion of the wellbore casing 200. In this manner, theradially expanded tubular member 240 is coupled to the lower portion ofthe wellbore casing 200. In an exemplary embodiment, the upper sealingmembers 245 are positioned in opposing relation to the lower portion ofthe wellbore casing 200 and the lower sealing members 250 are positionedin opposing relation to the walls of the open hole wellbore section 205.In this manner, the interface between the radially expanded tubularmember 240 and the wellbore casing 200 and open hole wellbore section205 is optimally fluidicly sealed.

As illustrated in FIG. 2 b, the apparatus 215 is then anchored to theopen hole wellbore section 205 using the anchoring device 235. In anexemplary embodiment, the anchoring device 235 is pressurized and theexpandable element 260 is radially extended from the anchoring device235 causing the flexible coupling element 255 to radially expand intointimate contact with the walls of the open hole wellbore section 205.In this manner, the lower section 265 of the expandable tubular member240 is removably coupled to the walls of the open hole wellbore section205.

In an alternative embodiment, a compressible cement and/or epoxy is theninjected into the annular space between the unexpanded portion of thetubular member 240 and the wellbore casing 100 and/or the open holewellbore section 205. The compressible cement and/or epoxy is thenpermitted to at least partially cure prior to the initiation of theradial expansion process. In this manner, an annular structural supportand fluidic seal is provided around the tubular member 240.

As illustrated in FIG. 2 c, the expansion cone 230 is then axiallydisplaced by applying an axial force to the second support member 225.In an exemplary embodiment, the axial displacement of the expansion cone230 radially expands the expandable tubular member 240 into intimatecontact with the walls of the open hole wellbore section 205.

In an alternative embodiment, as illustrated in FIG. 2 d, the axialdisplacement of the expansion cone 230 is enhanced by injecting apressurized fluidic material into the annular space between the firstsupport member 220 and the second support member 225. In this manner, anupward axial force is applied to the lower annular face of the expansioncone 230 using the pressurized fluidic material. In this manner, atemporary need for increased axial force during the radial expansionprocess can be easily satisfied.

As illustrated in FIGS. 2 e and 2 f, after the expandable tubular member240 has been radially expanded by the axial displacement of theexpansion cone 230, the first support member 220 and the anchoringdevice 235 are preferably removed from expandable tubular member 240 byde-pressurizing the anchoring device 235 and then lifting the firstsupport member 220 and anchoring device 235 from the wellbore casing 200and the open hole wellbore section 205.

Referring to FIGS, 3 a, 3 b, 3 c, and 3 d, an alternative embodiment ofa method and apparatus for coupling an expandable tubular member to apreexisting structure will be described. Referring to FIG. 3 a, awellbore casing 300 is positioned within a subterranean formation 305.The wellbore casing 300 may be positioned in any orientation from thevertical direction to the horizontal direction. The wellbore casing 300further includes one or more openings 310 that may have been the resultof unintentional damage to the wellbore casing 300, or due to a priorperforation or fracturing operation performed upon the surroundingsubterranean formation 305. As will be recognized by persons havingordinary skill in the art, the openings 310 can adversely affect thesubsequent operation and use of the wellbore casing 300 unless they aresealed off.

In an exemplary embodiment, an apparatus 315 is utilized to seal off theopenings 310 in the wellbore casing 300. More generally, the apparatus315 is preferably utilized to form or repair wellbore casings,pipelines, or structural supports.

The apparatus 315 preferably includes a support member 320, an expansioncone 325, an anchoring device 330, an expandable tubular member 335, andone or more sealing members 340.

The support member 320 is preferably adapted to be coupled to a surfacelocation. The support member 320 is further coupled to the expansioncone 325 and the anchoring device 330. The support member 320 ispreferably adapted to convey pressurized fluidic materials and/orelectrical current and/or communication signals from a surface locationto the anchoring device 330. The support member 320 may, for example, beconventional commercially available slick wire, braided wire, coiledtubing, or drilling stock material.

The expansion cone 325 is coupled to the support member 320. Theexpansion cone 325 is preferably adapted to radially expand theexpandable tubular member 335 when the expansion cone 325 is axiallydisplaced relative to the expandable tubular member 335. In an exemplaryembodiment, the expansion cone 325 is provided substantially asdisclosed in one or more of the following: (1) U.S. utility patentapplication Ser. No. 09/454,139, attorney docket no. 25791.3.02, filedon Dec. 3, 1999, which claimed the benefit of the filing date of U.S.provisional patent application No. 60/111,293, attorney docket no.25791.3, filed on Dec. 7, 1998; (2) U.S. utility patent application Ser.No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/121,702, filed on Feb. 25, 1999; (3) U.S. utilitypatent application Ser. No. 09/502,350, attorney docket no. 25791.8.02,filed on Feb. 10, 2000, which claimed the benefit of the filing date ofU.S. provisional application No. 60/119,611, attorney docket no.25791.8; (4) U.S. utility patent application Ser. No. 09/440,338,attorney docket no. 25791.9.02, filed on Nov. 15, 1999, which claimedthe benefit of the filing date of U.S. provisional application No.60/108,558, attorney docket no. 25791.9, filed on Nov. 16, 1998; (5)U.S. provisional patent application No. 60/183,546, filed on Feb. 18,2000; (6) U.S. utility patent application Ser. No. 09/523,460, attorneydocket no. 25791.11.02, filed on Mar. 10, 2000, which claimed thebenefit of the filing date of U.S. provisional application No.60/124,042, filed on Mar. 11, 1999; (7) U.S. utility patent applicationSer. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24,2000, which claimed the benefit of the filing dates of U.S. provisionalapplication No. 60/121,841, attorney docket no. 25791.12, filed on Feb.26, 1999 and U.S. provisional application No. 60/154,047, attorneydocket no. 25791.29, filed on Sep. 16, 1999; (8) U.S. utilityapplication Ser. No. 09/511,941, attorney docket no. 25791.16.02, filedon Feb. 24, 2000, which claimed the benefit of the filing date of U.S.provisional Ser. No. 60/121,907, attorney docket no. 25791.16, filed onFeb. 26, 1999; (9) U.S. utility patent application Ser. No. 09/588,946,attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claimedthe benefit of the filing date of U.S. provisional patent applicationSer. No. 60/137,998, attorney docket no. 25791.17, filed on Jun. 7,1999; (10) U.S. utility patent application Ser. No. 09/559,122, attorneydocket no. 25791.23.02, filed on Apr. 26, 2000, which claimed thebenefit of the filing date of U.S. provisional application No.60/131,106, attorney docket no. 25791.23, filed on Apr. 26, 1999; (11)U.S. provisional application No. 60/146,203, attorney docket no.25791.25, filed on Jul. 29, 1999; (12) U.S. provisional application No.60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999; (13)U.S. provisional patent application Ser. No. 60/162,671, attorney docketno. 25791.27, filed on Nov. 1, 1999; (14) U.S. provisional applicationNo. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999;(15) U.S. provisional patent application No. 60/159,033, attorney docketno. 25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patentapplication No. 60/165,228, attorney docket no. 25791.39, filed on Nov.12, 1999, the disclosures of which are incorporated herein by reference.

The anchoring device 330 is coupled to the support member 320 and theexpansion cone 325. The anchoring device 335 is preferably adapted tocontrollably coupled to the expandable tubular member 335 to thewellbore casing 300. In this manner, the anchoring device 330 preferablycontrollably anchors the expandable tubular member 335 to the wellborecasing 300 to facilitate the radial expansion of the expandable tubularmember 335 by the axial displacement of the expansion cone 325. In anexemplary embodiment, the anchoring device 330 includes one or moreexpandable elements 345 that are adapted to controllably extend from thebody of the anchoring device 330 to radially displace correspondingengagement elements 350 provided in the expandable tubular member 335.In an exemplary embodiment, the radial displacement of the engagementelements 350 couples the expandable tubular member 335 to the wellborecasing 300. In an exemplary embodiment, the expandable elements 345 arepistons that are actuated using fluidic pressure. In an exemplaryembodiment, the anchoring device 330 is any one of the hydraulicallyactuated anchoring devices commercially available from HalliburtonEnergy Services or Baker-Hughes.

In an alternative embodiment, the expandable elements 345 are explosivedevices that controllably generate a radially directed explosive forcefor radially displacing the engagement elements 350. In an exemplaryembodiment, the explosive expandable elements 345 are shaped explosivecharges commercially available from Halliburton Energy Services.

The expandable tubular member 335 is removably coupled to the expansioncone 325. In an exemplary embodiment, the expandable tubular member 335includes one or more engagement devices 350 that are adapted to beradially displaced by the anchoring device 330 into engagement with thewalls of the wellbore casing 300. In this manner, the expandable tubularmember 335 is coupled to the wellbore casing 300. In an exemplaryembodiment, the engagement devices 350 include teeth for biting into thesurface of the wellbore casing 100.

In an exemplary embodiment, the expandable tubular member 335 furtherincludes a lower section 355, an intermediate section 360, and an uppersection 365. In an exemplary embodiment, the lower section 355 includesthe engagement device 350 in order to provide anchoring at an endportion of the expandable tubular member 335. In an exemplaryembodiment, the wall thickness of the lower and intermediate sections,355 and 360, are less than the wall thickness of the upper section 365in order to optimally couple the radially expanded portion of theexpandable tubular member 335 to the wellbore casing 300.

In an exemplary embodiment, the expandable tubular member 335 is furtherprovided substantially as disclosed in one or more of the following: (1)U.S. utility patent application Ser. No. 09/454,139, attorney docket no.25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of thefiling date of U.S. provisional patent application No. 60/111,293,attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utilitypatent application Ser. No. 09/510,913, attorney docket no. 25791.7.02,filed on Feb. 23, 2000, which claimed the benefit of the filing date ofU.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3)U.S. utility patent application Ser. No. 09/502,350, attorney docket no.25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of thefiling date of U.S. provisional application No. 60/119,611, attorneydocket no. 25791.8; (4) U.S. utility patent application Ser. No.09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/108,558, attorney docket no. 25791.9, filed on Nov.16, 1998; (5) U.S. provisional patent application No. 60/183,546, filedon Feb. 18, 2000; (6) U.S. utility patent application Ser. No.09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utilitypatent application Ser. No. 09/512,895, attorney docket no. 25791.12.02,filed on Feb. 24, 2000, which claimed the benefit of the filing dates ofU.S. provisional application No. 60/121,841, attorney docket no.25791.12, filed on Feb. 26, 1999 and U.S. provisional application No.60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8)U.S. utility application Ser. No. 09/511,941, attorney docket no.25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of thefiling date of U.S. provisional Ser. No. 60/121,907, attorney docket no.25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent applicationSer. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7,2000, which claimed the benefit of the filing date of U.S. provisionalpatent application Ser. No. 60/137,998, attorney docket no. 25791.17,filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No.09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/131,106, attorney docket no. 25791.23, filed on Apr.26, 1999; (11) U.S. provisional application No. 60/146,203, attorneydocket no. 25791.25, filed on Jul. 29, 1999; (12) U.S. provisionalapplication No. 60/143,039, attorney docket no. 25791.26, filed on Jul.9, 1999; (13) U.S. provisional patent application Ser. No. 60/162,671,attorney docket no. 25791.27, filed on Nov. 1, 1999; (14) U.S.provisional application No. 60/159,039, attorney docket no. 25791.36,filed on Oct. 12, 1999; (15) U.S. provisional patent application No.60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999; and(16) U.S. provisional patent application No. 60/165,228, attorney docketno. 25791.39, filed on Nov. 12, 1999, the disclosures of which areincorporated herein by reference.

The sealing members 340 are coupled to the outer surface of the upperportion 365 of the expandable tubular member 335. The sealing members340 are preferably adapted to engage and fluidicly seal the interfacebetween the radially expanded expandable tubular member 335 and thewellbore casing 300. In an exemplary embodiment, the apparatus 315includes a plurality of sealing members 340. In an exemplary embodiment,the sealing members 340 surround and isolate the opening 310.

As illustrated in FIG. 3 a, the apparatus 315 is preferably positionedwithin the wellbore casing 300 with the expandable tubular member 335positioned in opposing relation to the opening 310. In an exemplaryembodiment, the apparatus 315 includes a plurality of sealing members340 that are positioned above and below the opening 310. In this manner,the radial expansion of the expandable tubular member 335 optimallyfluidicly isolates the opening 310.

As illustrated in FIG. 3 b, the expandable tubular member 335 of theapparatus 315 is then anchored to the wellbore casing 300 using theanchoring device 330. In an exemplary embodiment, the anchoring device330 is pressurized and the expandable element 345 is extended from theanchoring device 330 and radially displaces the corresponding engagementelements 350 of the expandable tubular member 335 into intimate contactwith the wellbore casing 300. In this manner, the lower section 355 ofthe expandable tubular member 335 is coupled to the wellbore casing 300.

In an alternative embodiment, a compressible cement and/or epoxy is theninjected into the annular space between the unexpanded portion of thetubular member 335 and the wellbore casing 300. The compressible cementand/or epoxy is then permitted to at least partially cure prior to theinitiation of the radial expansion process. In this manner, an annularstructural support and fluidic seal is provided around the tubularmember 335.

As illustrated in FIG. 3 c, the anchoring device 330 is then deactivatedand the expansion cone 325 is axially displaced by applying an axialforce to the support member 320. In an exemplary embodiment, thedeactivation of the anchoring device 330 causes the expandable elements345 to radially retract into the anchoring device 330. Alternatively,the expandable elements 345 are resiliently coupled to the anchoringdevice 330. In this manner, the expandable elements 345 retractautomatically upon the deactivation of the anchoring device 330. In anexemplary embodiment, the axial displacement of the expansion cone 325radially expands the expandable tubular member 335 into intimate contactwith the walls of the wellbore casing 300.

As illustrated in FIG. 3 d, after the expandable tubular member 335 hasbeen radially expanded by the axial displacement of the expansion cone335, the support member 320, expansion cone 325, and the anchoringdevice 330 are preferably removed from the expanded expandable tubularmember 335.

In an exemplary embodiment, the opening 310 in the wellbore casing 300is sealed off by the radially expanded tubular member 335. In thismanner, repairs to the wellbore casing 300 are optimally provided. Moregenerally, the apparatus 315 is used to repair or form wellbore casings,pipelines, and structural supports.

Referring to FIG. 4, an embodiment of a system 400 for applying an axialforce to the expansion cones 130, 230, and 325 includes a lifting device405, a first support member 410, a shock absorber 415, and a secondsupport member 420. In an exemplary embodiment, the system 400 isadapted to minimize the transfer of shock loads, created during thecompletion of the radial expansion of tubular members by the expansioncones 130, 230, and 325, to the lifting device 405. In this manner, theradial expansion of tubular members by the expansion cones 130, 230 and325 is provided in an optimally safe manner.

The lifting device 405 is supported at a surface location and is coupledto the first support member 410. The lifting device 405 may comprise anynumber of conventional commercially available lifting devices suitablefor manipulating tubular members within a wellbore.

The first support member 410 is coupled to the lifting device 405 andthe shock absorber 415. The first support member 410 may comprise anynumber of conventional commercially available support members such as,for example, coiled tubing, a drill string, a wireline, braided wire, ora slick line.

The shock absorber 415 is coupled to the first support member 410 andthe second support member 420. The shock absorber 415 is preferablyadapted to absorb shock loads transmitted from the second support member420. The shock absorber 415 may be any number of conventionalcommercially available shock absorbers.

The second support member 420 is coupled to the shock absorber 415. Thesecond support member 420 is further preferably adapted to be coupled toone or more of the expansion cones 130, 230 and 325.

In an exemplary embodiment, during operation of the system 400, thelifting device applies an axial force to one of the expansion cones 130,230 and 325 in order to radially expand tubular members. In an exemplaryembodiment, upon the completion of the radial expansion process, whenthe expansion cones 130, 230 and 325, exit the radially expanded tubularmembers, the sudden shock loads generated are absorbed, or at leastminimized, by the shock absorber 415. In this manner, the radialexpansion of tubular members by pulling the expansion cones 130, 230 and325 using the lifting device 405 is provided in an optimally safemanner.

Referring to FIG. 5, an embodiment of a coupling system 500 for use inthe expandable tubular members 140, 240, and 335 will now be described.In an exemplary embodiment, the system 500 includes an upper ring 505, asealing element 510, and a lower ring 515. In an exemplary embodiment,the upper ring 505, the sealing element 510, and the lower ring 515 areprovided on the outer surfaces of the expandable tubular members 140,240, and 335. In this manner, when the expandable tubular members 140,240 and 335 are radially expanded, the upper ring 505, the sealingelement 510, and the lower ring 515 engage the interior surface of thepreexisting structure that the expandable tubular members 140, 240 and335 are coupled to. In an exemplary embodiment, the upper and lowerrings, 505 and 515, penetrate the interior surface of the preexistingstructure that the expandable tubular members 140, 240 and 335 arecoupled to in order to optimally anchor the tubular members 140, 240 and335 to the preexisting structure. In an exemplary embodiment, thesealing element 510 is compressed into contact with the interior surfaceof the preexisting structure that the expandable tubular members 140,240 and 335 are coupled to in order to optimally fluidicly seal theinterface between the tubular members 140, 240 and 335 and thepreexisting structure.

In an exemplary embodiment, the upper and lower rings, 505 and 515,extend from the outer surfaces of the tubular members 140, 240 and 335by a distance of about {fraction (1/64)} to 2 inches. In an exemplaryembodiment, the upper and lower rings, 505 and 515, extend about ⅛″ fromthe outer surfaces of the tubular members 140, 240, and 335 in order tooptimally engage the preexisting structure.

In an exemplary embodiment, the sealing element 510 extends from theouter surfaces of the tubular members 140, 240 and 335 by a distancesubstantially equal to the extension of the upper and lower rings, 505and 515, above the outer surfaces of the tubular members 140, 240 and335. In an exemplary embodiment, the sealing element 510 is fabricatedfrom rubber in order to optimally fluidicly seal and engage thepreexisting structure.

In an exemplary embodiment, the tubular members 140, 240 and 335 includea plurality of the coupling systems 500. In an exemplary embodiment, thecoupling systems 500 are provided on the lower, intermediate, and upperportions of the tubular members 140, 240, and 335.

Referring now to FIG. 6, an exemplary embodiment of an expandabletubular member 600 for use in the apparatus 115, 215 and 315 will bedescribed. The tubular member 600 preferably includes a lower portion605, an intermediate portion 610, and an upper portion 615.

The lower portion 605 is coupled to the intermediate portion 610. In anexemplary embodiment, the lower portion 605 is further adapted to matewith the anchoring devices 135, 235, and 330. In an exemplaryembodiment, the lower portion 605 further preferably includes one ormore slotted portions 620 for facilitating the radial expansion of thelower portion 605 by the anchoring devices 135, 235, and 330. In thismanner, the lower portion 605 of the tubular member 600 is preferablyradially expanded by the anchoring devices 135, 235, and 330 intocontact with the preexisting structure. Furthermore, in this manner, thelower portion 605 of the tubular member 600 is anchored to thepreexisting structure prior to the initiation of the radial expansionprocess.

The intermediate portion 610 is coupled to the lower portion 605 and theupper portion 615. In an exemplary embodiment, the wall thicknesses ofthe lower and intermediate portions, 605 and 610, are less than the wallthickness of the upper portion 615 in order to facilitate the radialexpansion of the tubular member 600. In an exemplary embodiment, thelower and intermediate portions, 605 and 610, are preexpanded to matewith the expansion cone.

Referring to FIG. 7, an exemplary embodiment of an expandable tubularmember 700 for use in the apparatus 115, 215 and 315 will be described.In an exemplary embodiment, the tubular member 700 minimizes the shockloads created upon the completion of the radial expansion process. In anexemplary embodiment, the tubular member 700 includes a lower portion705, a lower transitionary portion 710, an intermediate portion 715, anupper transitionary portion 720, an upper portion 725, and a sealingelement 730.

The lower portion 705 is coupled to the lower transitionary portion 710.The lower portion 705 is preferably adapted to mate with the expansioncone and the anchoring device.

The lower transitionary portion 710 is coupled to the lower portion 705and the intermediate portion 715. In an exemplary embodiment, the lowertransitionary portion 710 is adapted to mate with the expansion cone. Inan exemplary embodiment, the wall thicknesses of the lower portion 705and the lower transitionary portion 710 are less than the wallthicknesses of the intermediate portion 715, the upper transitionaryportion 720 and the upper portion 725 in order to optimally facilitatethe radial expansion process.

The intermediate portion 715 is coupled to the lower transitionaryportion 710 and the upper transitionary portion 720. In an exemplaryembodiment, the outside diameter of the intermediate portion 715 is lessthan the wall thicknesses of the lower portion 705 and the upper portion725.

The upper transitionary portion 720 is coupled to the intermediateportion 715 and the upper portion 725.

The upper portion 725 is coupled to the upper transitionary portion 720.

The sealing element 730 is coupled to the outside surface of theintermediate portion 715. In an exemplary embodiment, the outsidediameter of the sealing element 730 is less than or equal to the outsidediameter of the lower portion 705 and the upper portion 725 in order tooptimally protect the sealing element 703 during placement of thetubular member 700 within the preexisting structure.

In an exemplary embodiment, during the radial expansion of the tubularmember 700 using the apparatus 115, 215 and 315, the preexpansion of theupper transitionary portion 720 and the upper portion 725 reduces theshock loads typically created during the end portion of the radialexpansion process. In this manner, the radial expansion process isoptimally provided in a safe manner. Furthermore, because the sealingelement 730 is preferably recessed below the surfaces of the lowerportion 705 and the upper portion 725, the sealing element 730 isoptimally protected from damage during the placement of the tubularmember 700 within the preexisting structure.

Referring to FIG. 8, an exemplary embodiment of an expandable tubularmember 800 for use in the apparatus 115, 215 and 315 will be described.The tubular member 800 preferably includes a lower portion 805, anintermediate portion 810, and an upper portion 815.

The lower portion 805 is coupled to the intermediate portion 810. In anexemplary embodiment, the lower portion 805 is further adapted to matewith the expansion cones 130, 230, 325 and the anchoring devices 135,235, and 330.

The intermediate portion 810 is coupled to the lower portion 805 and theupper portion 815. In an exemplary embodiment, the wall thicknesses ofthe lower and intermediate portions, 805 and 810, are less than the wallthickness of the upper portion 815 in order to facilitate the radialexpansion of the tubular member 800. In an exemplary embodiment, thelower and intermediate portions, 805 and 810, are preexpanded to matewith the expansion cone.

The upper portion 815 is coupled to the intermediate portion 810. In anexemplary embodiment, the upper portion 815 further preferably includesone or more slotted portions 820 for facilitating the radial expansionof the upper portion 815 by the expansion cones 130, 230, and 325. Inthis manner, the upper portion 815 of the tubular member 800 ispreferably radially expanded by the expansion cones 130, 230, and 325with minimal shock loads when the expansion cones 130, 230 and 325 exitthe expandable tubular member 800.

Referring to FIG. 9, an exemplary embodiment of a method of applying anaxial force to the expansion cones 130, 230, and 325 will now bedescribed. In an exemplary embodiment, the axial displacement of theexpansion cones 130, 230, and 325 during the radial expansion process isprovided by applying an axial force to the expansion cones 130, 230, and325. In an exemplary embodiment, the axial force provided includes theapplication of a substantially constant axial force for some timeperiods and the application of increased axial force for other timeperiods in order to optimally facilitate the radial expansion process byminimizing the effects of friction. In an exemplary embodiment, theapplication of the increased axial force is provided on a periodic basisin order to optimally provide a variable contact area between theexpansion cone and the tubular member being expanded. In an alternativeembodiment, the application of the increased axial force is provided ona random basis in order to optimally provide a variable contact areabetween the expansion cone and the tubular member being expanded. In anexemplary embodiment, the duty cycle of the application of constant andincreased axial forces ranges from about 90/10% to 60/40% in order tooptimally radially expand the tubular members. In an exemplaryembodiment, the ratio of the increased axial force to the substantiallyconstant axial force ranges from about 1.5 to 1 to about 4 to 1 in orderto optimally provide a variable contact area between the expansion coneand the tubular member being expanded, promote more even wear of theexpansion cone, and clean debris from the expansion cone surface.

Referring to FIGS.10 a to 10 i, an embodiment of an apparatus and methodfor forming a wellbore casing will now be described. As illustrated inFIG. 10 a, a wellbore casing 1000 and an open hole wellbore section 1005are provided in a subterranean formation 1010. The wellbore casing 1000and open hole wellbore section 1005 may be orientated at any orientationranging from the vertical to the horizontal. In an exemplary embodiment,a new section of wellbore casing is formed in the open hole wellboresection 1005 using an apparatus 1015. More generally, the apparatus 1015is utilized to form or repair wellbore casings, pipelines, or structuralsupports.

The apparatus 1015 preferably includes a first support member 1020, asecond support member 1025, an expansion cone 1030, an anchoring device1035, an expandable tubular member 1040, one or more upper sealingmembers 1045, one or more lower sealing members 1050, and a flexiblecoupling element 1055.

The first support member 1020 is preferably adapted to be coupled to asurface location. The first support member 1020 is further coupled tothe anchoring device 1035. The first support member 1020 is preferablyadapted to convey pressurized fluidic materials and/or electricalcurrent and/or communication signals from a surface location to theanchoring device 1035. The first support member 1020 may, for example,be conventional commercially available slick wire, braided wire, coiledtubing, or drilling stock material.

The second support member 1025 is preferably adapted to be coupled to asurface location. The second support member 1025 is further coupled tothe expansion cone 1030. The second support member 1025 is preferablyadapted to permit the expansion cone 1030 to be axially displacedrelative to the first support member 1020. The second support member1025 may, for example, be conventional commercially available slickwire, braided wire, coiled tubing, or drilling stock material.

In an alternative embodiment, the support member 1020 is telescopicallycoupled to the support member 1025, and the support member 1025 iscoupled to a surface support member.

The expansion cone 1030 is coupled to the second support member 1025.The expansion cone 1030 is preferably adapted to radially expand theexpandable tubular member 1040 when the expansion cone 1030 is axiallydisplaced relative to the expandable tubular member 1040. In anexemplary embodiment, the expansion cone 1030 is provided substantiallyas disclosed in one or more of the following: (1) U.S. utility patentapplication Ser. No. 09/454,139, attorney docket no. 25791.3.02, filedon Dec. 3, 1999, which claimed the benefit of the filing date of U.S.provisional patent application No. 60/111,293, attorney docket no.25791.3, filed on Dec. 7, 1998; (2) U.S. utility patent application Ser.No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/121,702, filed on Feb. 25, 1999; (3) U.S. utilitypatent application Ser. No. 09/502,350, attorney docket no. 25791.8.02,filed on Feb. 10, 2000, which claimed the benefit of the filing date ofU.S. provisional application No. 60/119,611, attorney docket no.25791.8; (4) U.S. utility patent application Ser. No. 09/440,338,attorney docket no. 25791.9.02, filed on Nov. 15, 1999, which claimedthe benefit of the filing date of U.S. provisional application No.60/108,558, attorney docket no. 25791.9, filed on Nov. 16, 1998; (5)U.S. provisional patent application No. 60/183,546, filed on Feb. 18,2000; (6) U.S. utility patent application Ser. No. 09/523,460, attorneydocket no. 25791.11.02, filed on Mar. 10, 2000, which claimed thebenefit of the filing date of U.S. provisional application No.60/124,042, filed on Mar. 11, 1999; (7) U.S. utility patent applicationSer. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24,2000, which claimed the benefit of the filing dates of U.S. provisionalapplication No. 60/121,841, attorney docket no. 25791.12, filed on Feb.26, 1999 and U.S. provisional application No. 60/154,047, attorneydocket no. 25791.29, filed on Sep. 16, 1999; (8) U.S. utilityapplication Ser. No. 09/511,941, attorney docket no. 25791.16.02, filedon Feb. 24, 2000, which claimed the benefit of the filing date of U.S.provisional Ser. No. 60/121,907, attorney docket no. 25791.16, filed onFeb. 26, 1999; (9) U.S. utility patent application Ser. No. 09/588,946,attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claimedthe benefit of the filing date of U.S. provisional patent applicationSer. No. 60/137,998, attorney docket no. 25791.17, filed on Jun. 7,1999; (10) U.S. utility patent application Ser. No. 09/559,122, attorneydocket no. 25791.23.02, filed on Apr. 26, 2000, which claimed thebenefit of the filing date of U.S. provisional application No.60/131,106, attorney docket no. 25791.23, filed on Apr. 26, 1999; (11)U.S. provisional application No. 60/146,203, attorney docket no.25791.25, filed on Jul. 29, 1999; (12) U.S. provisional application No.60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999; (13)U.S. provisional patent application Ser. No. 60/162,671, attorney docketno. 25791.27, filed on Nov. 1, 1999; (14) U.S. provisional applicationNo. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999;(15) U.S. provisional patent application No. 60/159,033, attorney docketno. 25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patentapplication No. 60/165,228, attorney docket no. 25791.39, filed on Nov.12, 1999, the disclosures of which are incorporated herein by reference.

The anchoring device 1035 is coupled to the first support member 1020.The anchoring device 1035 is preferably adapted to be controllablycoupled to the expandable tubular member 1040 and the open hole wellboresection 1005. In this manner, the anchoring device 1035 preferablycontrollably anchors the expandable tubular member 1040 to the open holewellbore section 1005 to facilitate the radial expansion of theexpandable tubular member 1040 by the axial displacement of theexpansion cone 1030.

In an exemplary embodiment, the anchoring device 1035 includes one ormore expandable elements 1060 that are adapted to controllably extendfrom the body of the anchoring device 1035 to engage both the flexiblecoupling element 1055 and the open hole wellbore section 1005. In anexemplary embodiment, the expandable elements 1060 are actuated usingfluidic pressure.

In an exemplary embodiment, the anchoring device 1035 further includes afluid passage 1036 adapted to receive a ball plug or other similarvalving element. In this manner, fluidic materials can be exhausted fromthe anchoring device 1035 and the fluid passage 1036 can be controllablyplugged. In an exemplary embodiment, the anchoring-device 1035 is anyone of the hydraulically actuated packers commercially available fromHalliburton Energy Services or Baker-Hughes, modified in accordance withthe teachings of the present disclosure.

In an exemplary embodiment, the anchoring devices 135, 235, and 330 arealso modified to includes a fluid passage that can be controllablyplugged in order to permit fluidic materials to be exhausted from theanchoring devices 135, 235, and 330.

The expandable tubular member 1040 is removably coupled to the expansioncone 1030. The expandable tubular member 1040 is further preferablycoupled to the flexible coupling element 1055.

In an exemplary embodiment, the expandable tubular member 1040 furtherincludes a lower section 1065, an intermediate section 1070, and anupper section 1075. In an exemplary embodiment, the lower section 1065is coupled to the flexible coupling element 1055 in order to provideanchoring at an end portion of the expandable tubular member 1040. In anexemplary embodiment, the wall thickness of the lower and intermediatesections, 1065 and 1070, are less than the wall thickness of the uppersection 1075 in order to optimally couple the radially expanded portionof the expandable tubular member 1040 to the wellbore casing 1000 andthe open hole wellbore section 1005.

In an exemplary embodiment, the expandable tubular member 1040 isfurther provided substantially as disclosed in one or more of thefollowing: (1) U.S. utility patent application Ser. No. 09/454,139,attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed thebenefit of the filing date of U.S. provisional patent application no.60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S.utility patent application Ser. No. 09/510,913, attorney docket no.25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of thefiling date of U.S. provisional application No. 60/121,702, filed onFeb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350,attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimedthe benefit of the filing date of U.S. provisional application No.60/119,611, attorney docket no. 25791.8; (4) U.S. utility patentapplication Ser. No. 09/440,338, attorney docket no. 25791.9.02, filedon Nov. 15, 1999, which claimed the benefit of the filing date of U.S.provisional application No. 60/108,558, attorney docket no. 25791.9,filed on Nov. 16, 1998; (5) U.S. provisional patent application No.60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent applicationSer. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10,2000, which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utilitypatent application Ser. No. 09/512,895, attorney docket no. 25791.12.02,filed on Feb. 24, 2000, which claimed the benefit of the filing dates ofU.S. provisional application No. 60/121,841, attorney docket no.25791.12, filed on Feb. 26, 1999 and U.S. provisional application No.60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8)U.S. utility application Ser. No. 09/511,941, attorney docket no.25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of thefiling date of U.S. provisional Ser. No. 60/121,907, attorney docket no.25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent applicationSer. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7,2000, which claimed the benefit of the filing date of U.S. provisionalpatent application Ser. No. 60/137,998, attorney docket no. 25791.17,filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No.09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/131,106, attorney docket no. 25791.23, filed on Apr.26, 1999; (11) U.S. provisional application No. 60/146,203, attorneydocket no. 25791.25, filed on Jul. 29, 1999; (12) U.S. provisionalapplication No. 60/143,039, attorney docket no. 25791.26, filed on Jul.9, 1999; (13) U.S. provisional patent application Ser. No. 60/162,671,attorney docket no. 25791.27, filed on Nov. 1, 1999; (14) U.S.provisional application No. 60/159,039, attorney docket no. 25791.36,filed on Oct. 12, 1999; (15) U.S. provisional patent application No.60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999; and(16) U.S. provisional patent application No. 60/165,228, attorney docketno. 25791.39, filed on Nov. 12, 1999, the disclosures of which areincorporated herein by reference.

In an exemplary embodiment, the expandable tubular member 1040 isfurther provided in accordance with the teachings of embodiments ofexpandable tubular members described above and illustrated in FIGS. 5-8.

The upper sealing members 1045 are coupled to the outer surface of theupper portion 1075 of the expandable tubular member 1040. The uppersealing members 1045 are preferably adapted to engage and fluidicly sealthe interface between the radially expanded expandable tubular member1040 and the wellbore casing 1000. In an exemplary embodiment, theapparatus 1015 includes a plurality of upper sealing members 1045.

The lower sealing members 1050 are coupled to the outer surface of theupper portion 1075 of the expandable tubular member 1040. The lowersealing members 1050 are preferably adapted to engage and fluidicly sealthe interface between the radially expanded expandable tubular member1040 and the open wellbore section 1005. In an exemplary embodiment, theapparatus 1015 includes a plurality of lower sealing members 1050.

The flexible coupling element 1055 is coupled to the lower portion 1065of the expandable tubular member 1040. The flexible coupling element1055 is preferably adapted to radially expanded by the anchoring device1035 into engagement within the walls of the open hole wellbore section1005. In this manner, the lower portion 1065 of the expandable tubularmember 1040 is coupled to the walls of the open hole wellbore section1005. In an exemplary embodiment, the flexible coupling element 1055 isa slotted tubular member. In an exemplary embodiment, the flexiblecoupling element 1055 includes one or more hook elements for engagingthe walls of the open hole wellbore section 1005.

As illustrated in FIG. 10 a, the apparatus 1015 is preferably positionedwith the expandable tubular member 1040 positioned in overlappingrelation with a portion of the wellbore casing 1000. In this manner, theradially expanded tubular member 1040 is coupled to the lower portion ofthe wellbore casing 1000. In an exemplary embodiment, the upper sealingmembers 1045 are positioned in opposing relation to the lower portion ofthe wellbore casing 1000 and the lower sealing members 1050 arepositioned in opposing relation to the walls of the open hole wellboresection 1005. In this manner, the interface between the radiallyexpanded tubular member 1040 and the wellbore casing 1000 and open holewellbore section 1005 is optimally fluidicly sealed.

As illustrated in FIG. 10 b, in an exemplary embodiment, a quantity of anon-hardenable fluidic material is then injected into and then out ofthe apparatus 1015. In an exemplary embodiment, the non-hardenablematerial is discharged from the apparatus 1015 using the valveable flowpassage 1065. The non-hardenable fluidic material may be any number ofconventional commercially available fluidic materials such as, forexample, drilling mud.

As illustrated in FIG. 10 c, in an exemplary embodiment, a quantity of ahardenable fluidic sealing material is then injected into and out of theapparatus 1015. In an exemplary embodiment, the hardenable fluidicsealing material is exhausted from the apparatus 1015 using thevalveable flow passage 1065. In an exemplary embodiment, the hardenablefluidic sealing material is permitted to completely fill the annularspace between the tubular member 1040 and the open hole wellbore section1005. The hardenable fluidic sealing material may be any number ofconventional commercially available materials such as, for example,cement, slag mix and/or epoxy resin. In this manner, a fluidic sealingannular element is provided around the radially expanded tubular member1040.

As illustrated in FIG. 10 d, in an exemplary embodiment, anotherquantity of a non-hardenable fluidic material is then injected into andout of the apparatus 1015. In an exemplary embodiment, a ball plug ordart 1080, or other similar fluid passage blocking device, is placedinto the non-hardenable fluid material. In an exemplary embodiment, theball plug 1080 then seats in and seals off the valveable fluid passage1065. In this manner, the anchoring device 1035 is then pressurized toanchor the tubular member 1040 to the open hole wellbore section 1005.

In an alternative embodiment, the valveable fluid passage 1065 includesa remote or pressure activated valve for sealing off the valveable fluidpassage 1065.

As illustrated in FIG. 10 e, in an exemplary embodiment, the apparatus1015 is then anchored to the open hole wellbore section 1005 using theanchoring device 1035. In an exemplary embodiment, the anchoring device1035 is pressurized and the expandable element 1060 is radially extendedfrom the anchoring device 1035 causing the flexible coupling element1055 to radially expand into intimate contact with the walls of the openhole wellbore section 1005. In this manner, the lower section 1065 ofthe expandable tubular member 1040 is removably coupled to the walls ofthe open hole wellbore section 1005.

As illustrated in FIG. 10f, the expansion cone 1030 is then axiallydisplaced by applying an axial force to the second support member 1025.In an exemplary embodiment, the axial displacement of the expansion cone1030 radially expands the expandable tubular member 1040 into intimatecontact with the walls of the open hole wellbore section 1005.

In an alternative embodiment, as illustrated in FIG. 10 g, the axialdisplacement of the expansion cone 1030 is enhanced by injecting apressurized fluidic material into the annular space between the firstsupport member 1020 and the second support member 1025. In this manner,an upward axial force is applied to the lower annular face of theexpansion cone 1030 using the pressurized fluidic material. In thismanner, a temporary need for increased axial force during the radialexpansion process can be easily satisfied.

In an exemplary embodiment, the hardenable fluidic sealing material isthen permitted to at least partial cure.

As illustrated in FIGS. 10 h and 10 i, after the expandable tubularmember 1040 has been radially expanded by the axial displacement of theexpansion cone 1030, the first support member 1020 and the anchoringdevice 1035 are preferably removed from expandable tubular member 1040by de-pressurizing the anchoring device 1035 and then lifting the firstsupport member 1020 and anchoring device 1035 from the wellbore casing1000 and the open hole wellbore section 1005.

In an exemplary embodiment, the resulting new section of wellbore casingincludes the radially expanded tubular member 1040 and the outer annularlayer of the cured fluidic sealing material. In this manner, a newsection of wellbore casing is optimally provided. More generally, theapparatus 1015 is used to form and/or repair wellbore casings,pipelines, and structural supports.

Referring to FIGS. 11 a to 11 g, an alternative embodiment of anapparatus and method for coupling an expandable tubular member to apreexisting structure will now be described. Referring to FIG. 11 a, awellbore casing 1100 is positioned within a subterranean formation 1105.The wellbore casing 1100 may be positioned in any orientation from thevertical direction to the horizontal direction. The wellbore casing 1100further includes one or more openings 1110 that may have been the resultof unintentional damage to the wellbore casing 1100, or due to a priorperforation or fracturing operation performed upon the surroundingsubterranean formation 1105. As will be recognized by persons havingordinary skill in the art, the openings 1110 can adversely affect thesubsequent operation and use of the wellbore casing 1100 unless they aresealed off.

In an exemplary embodiment, an apparatus 1115 is utilized to seal offthe openings 1110 in the wellbore casing 1100. More generally, theapparatus 1115 is preferably utilized to form or repair wellborecasings, pipelines, or structural supports.

The apparatus 1115 preferably includes a first support member 1120, asecond support member 1125, an expansion cone 1130, an anchoring device1135, and expandable tubular member 1140, and one or more sealingmembers 1145.

The first support member 1120 is preferably adapted to be coupled to asurface location. The first support member 1120 is further coupled tothe anchoring device 1135. The first support member 1120 is preferablyadapted to convey pressurized fluidic materials and/or electricalcurrent and/or communication signals from a surface location to theanchoring device 1135. The first support member 1120 preferably has asubstantially hollow annular cross sectional shape. The first supportmember 1120 may, for example, be fabricated from conventionalcommercially available slick wire, braided wire, coiled tubing, ordrilling stock material.

The second support member 1125 is preferably adapted to be coupled to asurface location. The second support member 1125 is further coupled tothe expansion cone 1130. The second support member 1125 is preferablyadapted to permit the expansion cone 1130 to be axially displacedrelative to the first support member 1120. The second support member1125 may, for example, be conventional commercially available slickwire, braided wire, coiled tubing, or drilling stock material.

In an exemplary embodiment, the first support member 1120 is coupled toa surface location by a slip joint and/or sliding sleeve apparatus thatis concentrically coupled to the second support member 1125.

The expansion cone 1130 is coupled to the second support member 1125.The expansion cone 1130 is preferably adapted to radially expand theexpandable tubular member 1140 when the expansion cone 1130 is axiallydisplaced relative to the expandable tubular member 1140. In anexemplary embodiment, the expansion cone 1130 is provided substantiallyas disclosed in one or more of the following: (1) U.S. utility patentapplication Ser. No. 09/454,139, attorney docket no. 25791.3.02, filedon Dec. 3, 1999, which claimed the benefit of the filing date of U.S.provisional patent application No. 60/111,293, attorney docket no.25791.3, filed on Dec. 7, 1998; (2) U.S. utility patent application Ser.No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/121,702, filed on Feb. 25, 1999; (3) U.S. utilitypatent application Ser. No. 09/502,350, attorney docket no. 25791.8.02,filed on Feb. 10, 2000, which claimed the benefit of the filing date ofU.S. provisional application No. 60/119,611, attorney docket no.25791.8; (4) U.S. utility patent application Ser. No. 09/440,338,attorney docket no. 25791.9.02, filed on Nov. 15, 1999, which claimedthe benefit of the filing date of U.S. provisional application No.60/108,558, attorney docket no. 25791.9, filed on Nov. 16, 1998; (5)U.S. provisional patent application No. 60/183,546, filed on Feb. 18,2000; (6) U.S. utility patent application Ser. No. 09/523,460, attorneydocket no. 25791.11.02, filed on Mar. 10, 2000, which claimed thebenefit of the filing date of U.S. provisional application No.60/124,042, filed on Mar. 11, 1999; (7) U.S. utility patent applicationSer. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24,2000, which claimed the benefit of the filing dates of U.S. provisionalapplication No. 60/121,841, attorney docket no. 25791.12, filed on Feb.26, 1999 and U.S. provisional application No. 60/154,047, attorneydocket no. 25791.29, filed on Sep. 16, 1999; (8) U.S. utilityapplication Ser. No. 09/511,941, attorney docket no. 25791.16.02, filedon Feb. 24, 2000, which claimed the benefit of the filing date of U.S.provisional Ser. No. 60/121,907, attorney docket no. 25791.16, filed onFeb. 26, 1999; (9) U.S. utility patent application Ser. No. 09/588,946,attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claimedthe benefit of the filing date of U.S. provisional patent applicationSer. No. 60/137,998, attorney docket no. 25791.17, filed on Jun. 7,1999; (10) U.S. utility patent application Ser. No. 09/559,122, attorneydocket no. 25791.23.02, filed on Apr. 26, 2000, which claimed thebenefit of the filing date of U.S. provisional application No.60/131,106, attorney docket no. 25791.23, filed on Apr. 26, 1999; (11)U.S. provisional application No. 60/146,203, attorney docket no.25791.25, filed on Jul. 29, 1999; (12) U.S. provisional application No.60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999; (13)U.S. provisional patent application Ser. No. 60/162,671, attorney docketno. 25791.27, filed on Nov. 1, 1999; (14) U.S. provisional applicationNo. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999;(15) U.S. provisional patent application No. 60/159,033, attorney docketno. 25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patentapplication No. 60/165,228, attorney docket no. 25791.39, filed on Nov.12, 1999, the disclosures of which are incorporated herein by reference.

The anchoring device 1135 is coupled to the first support member 1120.The anchoring device 1135 is preferably adapted to be controllablycoupled to the expandable tubular member 1140 and the wellbore casing1100. In this manner, the anchoring device 1135 preferably controllablyanchors the expandable tubular member 1140 to the wellbore casing 1100to facilitate the radial expansion of the expandable tubular member 1140by the axial displacement of the expansion cone 1130. In an exemplaryembodiment, the anchoring device 1135 includes one or more expandableelements 1150 that are adapted to controllably extend from the body ofthe anchoring device 1135 to engage both the expandable tubular member1140 and the wellbore casing 1100. In an exemplary embodiment, theexpandable elements 1150 are actuated using fluidic pressure. In anexemplary embodiment, the anchoring device 1135 is any one of thehydraulically actuated packers commercially available from HalliburtonEnergy Services or Baker-Hughes modified in accordance with theteachings of the present disclosure.

The expandable tubular member 1140 is removably coupled to the expansioncone 1130. The expandable tubular member 1140 is further preferablyadapted to be removably coupled to the expandable elements 1150 of theanchoring device 1135. In an exemplary embodiment, the expandabletubular member 1140 includes one or more anchoring windows 1155 forpermitting the expandable elements 1150 of the anchoring device 1135 toengage the wellbore casing 1100 and the expandable tubular member 1140.

In an exemplary embodiment, the expandable tubular member 1140 furtherincludes a lower section 1160, an intermediate section 1165, and anupper section 1170. In an exemplary embodiment, the lower section 1160rests upon and is supported by the expansion cone 1130. In an exemplaryembodiment, the intermediate section 1165 includes the anchoring windows1155 in order to provide anchoring at an intermediate portion of theexpandable tubular member 1140.

In an exemplary embodiment, the expandable tubular member 1140 isfurther provided substantially as disclosed in one or more of thefollowing: (1) U.S. utility patent application Ser. No. 09/454,139,attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed thebenefit of the filing date of U.S. provisional patent application No.60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S.utility patent application Ser. No. 09/510,913, attorney docket no.25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of thefiling date of U.S. provisional application No. 60/121,702, filed onFeb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350,attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimedthe benefit of the filing date of U.S. provisional application No.60/119,611, attorney docket no. 25791.8; (4) U.S. utility patentapplication Ser. No. 09/440,338, attorney docket no. 25791.9.02, filedon Nov. 15, 1999, which claimed the benefit of the filing date of U.S.provisional application No. 60/108,558, attorney docket no. 25791.9,filed on Nov. 16, 1998; (5) U.S. provisional patent application No.60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent applicationSer. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10,2000, which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utilitypatent application Ser. No. 09/512,895, attorney docket no. 25791.12.02,filed on Feb. 24, 2000, which claimed the benefit of the filing dates ofU.S. provisional application No. 60/121,841, attorney docket no.25791.12, filed on Feb. 26, 1999 and U.S. provisional application No.60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8)U.S. utility application Ser. No. 09/511,941, attorney docket no.25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of thefiling date of U.S. provisional Ser. No. 60/121,907, attorney docket no.25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent applicationSer. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7,2000, which claimed the benefit of the filing date of U.S. provisionalpatent application Ser. No. 60/137,998, attorney docket no. 25791.17,filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No.09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/131,106, attorney docket no. 25791.23, filed on Apr.26, 1999; (11) U.S. provisional application Ser. No. 60/146,203,attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S.provisional application No. 60/143,039, attorney docket no. 25791.26,filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No.60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14)U.S. provisional application Ser. No. 60/159,039, attorney docket no.25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patentapplication No. 60/159,033, attorney docket no. 25791.37, filed on Oct.12, 1999; and (16) U.S. provisional patent application No. 60/165,228,attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures ofwhich are incorporated herein by reference.

The sealing members 1145 are coupled to the outer surface of theexpandable tubular member 1140. The sealing members 1145 are preferablyadapted to engage and fluidicly seal the interface between the radiallyexpanded expandable tubular member 1140 and the wellbore casing 1100. Inan exemplary embodiment, the apparatus 1115 includes a plurality ofsealing members 1145. In an exemplary embodiment, the sealing members1145 surround and isolate the opening 1110.

As illustrated in FIG. 11 a, the apparatus 1115 is preferably positionedwithin the wellbore casing 1100 with the expandable tubular member 1140positioned in opposing relation to the opening 1110. In an exemplaryembodiment, the apparatus 1115 includes a plurality of sealing members1145 that are positioned above and below the opening 1110. In thismanner, the radial expansion of the expandable tubular member 1140optimally fluidicly isolates the opening 1110.

As illustrated in FIG. 11 b, the apparatus 1115 is then anchored to thewellbore casing 1100 using the anchoring device 1135. In an exemplaryembodiment, the anchoring device 1135 is pressurized and the expandableelement 1150 is extended from the anchoring device 1135 through thecorresponding anchoring window 1155 in the expandable tubular member1140 into intimate contact with the wellbore casing 1100. In thismanner, the intermediate section 1165 of the expandable tubular member1140 is removably coupled to the wellbore casing 1100.

In an alternative embodiment, a compressible cement and/or epoxy is theninjected into at least a portion of the annular space between theunexpanded portion of the tubular member 1140 and the wellbore casing1100. The compressible cement and/or epoxy is then permitted to at leastpartially cure prior to the initiation of the radial expansion process.In this manner, an annular structural support and fluidic seal isprovided around the tubular member 1140.

As illustrated in FIG. 11 c, in an exemplary embodiment, the expansioncone 1130 is then axially displaced by applying an axial force to thesecond support member 1125. In an exemplary embodiment, the axialdisplacement of the expansion cone 1130 radially expands the lowersection 1160 of the expandable tubular member 1140 into intimate contactwith the walls of the wellbore or the wellbore casing 1100.

As illustrated in FIG. 11 d, in an exemplary embodiment, the axialdisplacement of the expansion cone 1130 is stopped once the expansioncone 1130 contacts the lower portion of the anchoring device 1135.

As illustrated in FIG. 11 e, in an exemplary embodiment, the anchoringdevice 1135 is then decoupled from the wellbore casing 1100 and theexpandable tubular member 1140.

As illustrated in FIG. 11 f, in an exemplary embodiment, the axialdisplacement of the expansion cone 1130 is then resumed. In an exemplaryembodiment, the anchoring device 1135 is also axial displaced. In thismanner, the lower section 1160 of the expandable tubular member 1140 isself-anchored to the wellbore casing 1100. In an exemplary embodiment,the lower section 1160 of the expandable tubular member 1140 includesone or more outer rings or other coupling members to facilitate theself-anchoring of the lower section 1160 of the expandable tubularmember 1140 to the wellbore or the wellbore casing 1100.

As illustrated in FIGS. 11 g, after the expandable tubular member 1140has been completely radially expanded by the axial displacement of theexpansion cone 1130, the 1110 in the wellbore casing 1100 is sealed offby the radially expanded tubular member 1140. In this manner, repairs tothe wellbore casing 1100 are optimally provided. More generally, theapparatus 1115 is used to repair or form wellbore casings, pipelines,and structural supports. In an exemplary embodiment, the inside diameterof the radially expanded tubular member 1140 is substantially constant.

Referring to FIGS. 12 a to 12 d, an alternative embodiment of anapparatus and method for coupling an expandable tubular member to apreexisting structure will now be described. Referring to FIG. 12 a, awellbore casing 1200 is positioned within a subterranean formation 1205.The wellbore casing 1200 may be positioned in any orientation from thevertical direction to the horizontal direction. The wellbore casing 1200further includes one or more openings 1210 that may have been the resultof unintentional damage to the wellbore casing 1200, or due to a priorperforation or fracturing operation performed upon the surroundingsubterranean formation 1205. As will be recognized by persons havingordinary skill in the art, the openings 1210 can adversely affect thesubsequent operation and use of the wellbore casing 1200 unless they aresealed off.

In an exemplary embodiment, an apparatus 1215 is utilized to seal offthe openings 1210 in the wellbore casing 1200. More generally, theapparatus 1215 is preferably utilized to form or repair wellborecasings, pipelines, or structural supports.

The apparatus 1215 preferably includes a support member 1220, anexpandable expansion cone 1225, an expandable tubular member 1235, andone or more sealing members 1240.

The support member 1220 is preferably adapted to be coupled to a surfacelocation. The support member 1220 is further coupled to the expandableexpansion cone 1225. The support member 320 is preferably adapted toconvey pressurized fluidic materials and/or electrical current and/orcommunication signals from a surface location to the expandableexpansion cone. The support member 1220 may, for example, beconventional commercially available slick wire, braided wire, coiledtubing, or drilling stock material.

The expandable expansion cone 1225 is coupled to the support member1220. The expandable expansion cone 1225 is preferably adapted toradially expand the expandable tubular member 1235 when the expandableexpansion cone 1225 is axially displaced relative to the expandabletubular member 1235. The expandable expansion cone 1225 is furtherpreferably adapted to radially expand at least a portion of theexpandable tubular member 1235 when the expandable expansion cone 1225is controllably radially expanded. The expandable expansion cone 1225may be any number of conventional commercially available radiallyexpandable expansion cones. In an exemplary embodiment, the expandableexpansion cone 1225 is provided substantially as disclosed in U.S. Pat.No. 5,348,095, the disclosure of which is incorporated herein byreference.

In an exemplary embodiment, the expansion cone 1225 is further providedsubstantially as disclosed in one or more of the following: (1) U.S.utility patent application Ser. No. 09/454,139, attorney docket no.25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of thefiling date of U.S. provisional patent application No. 60/111,293,attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utilitypatent application Ser. No. 09/510,913, attorney docket no. 25791.7.02,filed on Feb. 23, 2000, which claimed the benefit of the filing date ofU.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3)U.S. utility patent application Ser. No. 09/502,350, attorney docket no.25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of thefiling date of U.S. provisional application No. 60/119,611, attorneydocket no. 25791.8; (4) U.S. utility patent application Ser. No.09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/108,558, attorney docket no. 25791.9, filed on Nov.16, 1998; (5) U.S. provisional patent application No. 60/183,546, filedon Feb. 18, 2000; (6) U.S. utility patent application Ser. No.09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utilitypatent application Ser. No. 09/512,895, attorney docket no. 25791.12.02,filed on Feb. 24, 2000, which claimed the benefit of the filing dates ofU.S. provisional application No. 60/121,841, attorney docket no.25791.12, filed on Feb. 26, 1999 and U.S. provisional application Ser.No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999;(8) U.S. utility application Ser. No. 09/511,941, attorney docket no.25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of thefiling date of U.S. provisional Ser. No. 60/121,907, attorney docket no.25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent applicationSer. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7,2000, which claimed the benefit of the filing date of U.S. provisionalpatent application Ser. No. 60/137,998, attorney docket no. 25791.17,filed on Jun. 17, 1999; (10) U.S. utility patent application Ser. No.09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/131,106, attorney docket no. 25791.23, filed on Apr.26, 1999; (11) U.S. provisional application Ser. No. 60/146,203,attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S.provisional application No. 60/143,039, attorney docket no. 25791.26,filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No.60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14)U.S. provisional application Ser. No. 60/159,039, attorney docket no.25791.36, filed on 10/12,1999; (15) U.S. provisional patent applicationNo. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999;and (16) U.S. provisional patent application No. 60/165,228, attorneydocket no. 25791.39, filed on Nov. 12, 1999, the disclosures of whichare incorporated herein by reference.

The expandable tubular member 1235 is removably coupled to the expansioncone 1225. In an exemplary embodiment, the expandable tubular member1235 includes one or more engagement devices 1250 that are adapted tocouple with and penetrate the wellbore casing 1200. In this manner, theexpandable tubular member 1235 is optimally coupled to the wellborecasing 1200. In an exemplary embodiment, the engagement devices 1250include teeth for biting into the surface of the wellbore casing 1200.

In an exemplary embodiment, the expandable tubular member 1235 furtherincludes a lower section 1255, an intermediate section 1260, and anupper section 1265. In an exemplary embodiment, the lower section 1255includes the engagement devices 1250 in order to provide anchoring at anend portion of the expandable tubular member 1235. In an exemplaryembodiment, the wall thickness of the lower and intermediate sections,1255 and 1260, are less than the wall thickness of the upper section1265 in order to optimally facilitate the radial expansion of the lowerand intermediate sections, 1255 and 1260, of the expandable tubularmember 1235. In an alternative embodiment, the lower section 1255 of theexpandable tubular member 1235 is slotted in order to optimallyfacilitate the radial expansion of the lower section 1255 of theexpandable tubular member 1235 using the expandable expansion cone 1225.

In an exemplary embodiment, the expandable tubular member 1235 isfurther provided substantially as disclosed in one or more of thefollowing: (1) U.S. utility patent application Ser. No. 09/454,139,attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed thebenefit of the filing date of U.S. provisional patent application No.60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S.utility patent application Ser. No. 09/510,913, attorney docket no.25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of thefiling date of U.S. provisional application No. 60/121,702, filed onFeb. 25, 1999; (3) U.S. utility patent application serial no.09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/119,611, attorney docket no. 25791.8; (4) U.S.utility patent application Ser. No. 09/440,338, attorney docket no.25791.9.02, filed on Nov. 15, 1999, which claimed the benefit of thefiling date of U.S. provisional application No. 60/108,558, attorneydocket no. 25791.9, filed on Nov. 16, 1998; (5) U.S. provisional patentapplication No. 60/183,546, filed on Feb. 18, 2000; (6) U.S. utilitypatent application Ser. No. 09/523,460, attorney docket no. 25791.11.02,filed on Mar. 10, 2000, which claimed the benefit of the filing date ofU.S. provisional application No. 60/124,042, filed on Mar. 11, 1999; (7)U.S. utility patent application Ser. No. 09/512,895, attorney docket no.25791.12.02, filed on Feb. 24, 2000, which claimed the benefit of thefiling dates of U.S. provisional application No. 60/121,841, attorneydocket no. 25791.12, filed on Feb. 26, 1999 and U.S. provisionalapplication Ser. No. 60/154,047, attorney docket no. 25791.29, filed onSep. 16, 1999; (8) U.S. utility application Ser. No. 09/511,941,attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claimedthe benefit of the filing date of U.S. provisional Ser. No. 60/121,907,attorney docket no. 25791.16, filed on Feb. 26, 1999; (9) U.S. utilitypatent application Ser. No. 09/588,946, attorney docket no. 25791.17.02,filed on Jun. 7, 2000, which claimed the benefit of the filing date ofU.S. provisional patent application Ser. No. 60/137,998, attorney docketno. 25791.17, filed on Jun. 7, 1999; (10) U.S. utility patentapplication Ser. No. 09/559,122, attorney docket no. 25791.23.02, filedon Apr. 26, 2000, which claimed the benefit of the filing date of U.S.provisional application No. 60/131,106, attorney docket no. 25791.23,filed on Apr. 26, 1999; (11) U.S. provisional application Ser. No.60/146,203, attorney docket no. 25791.25, filed on Jul. 29, 1999; (12)U.S. provisional application No. 60/143,039, attorney docket no.25791.26, filed on Jul. 9, 1999; (13) U.S. provisional patentapplication Ser. No. 60/162,671, attorney docket no. 25791.27, filed onNov. 1, 1999; (14) U.S. provisional application Ser. No. 60/159,039,attorney docket no. 25791.36, filed on Oct. 12, 1999; (15) U.S.provisional patent application No. 60/159,033, attorney docket no.25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patentapplication No. 60/165,228, attorney docket no. 25791.39, filed on Nov.12, 1999, the disclosures of which are incorporated herein by reference.

The sealing members 1240 are preferably coupled to the outer surface ofthe upper portion 1265 of the expandable tubular member 1235. Thesealing members 1240 are preferably adapted to engage and fluidicly sealthe interface between the radially expanded expandable tubular member1235 and the wellbore casing 1200. In an exemplary embodiment, theapparatus 1215 includes a plurality of sealing members 1240. In anexemplary embodiment, the sealing members 1240 surround and isolate theopening 1210.

As illustrated in FIG. 12 a, the apparatus 1215 is preferably positionedwithin the wellbore casing 1200 with the expandable tubular member 1235positioned in opposing relation to the opening 1210. In an exemplaryembodiment, the apparatus 1215 includes a plurality of sealing members1240 that are positioned above and below the opening 1210. In thismanner, the radial expansion of the expandable tubular member 1235optimally fluidicly isolates the opening 1210.

As illustrated in FIG. 12 b, the expandable tubular member 1235 of theapparatus 1215 is then anchored to the wellbore casing 1200 by expandingthe expandable expansion cone 1225 into contact with the lower section1255 of the expandable tubular member 1235. In an exemplary embodiment,the lower section 1255 of the expandable tubular member 1235 is radiallyexpanded into intimate contact with the wellbore casing 1200. In anexemplary embodiment, the engagement devices 1250 are thereby coupledto, and at least partially penetrate into, the wellbore casing 1200. Inthis manner, the lower section 1255 of the expandable tubular member1235 is optimally coupled to the wellbore casing 1200.

In an alternative embodiment, a compressible cement and/or epoxy is theninjected into the annular space between the unexpanded portion of thetubular member 1235 and the wellbore casing 1200. The compressiblecement and/or epoxy may then be permitted to at least partially cureprior to the initiation of the radial expansion process. In this manner,an annular structural support and fluidic seal is provided around thetubular member 1235.

As illustrated in FIG. 12 c, the expandable expansion cone 1225 is thenaxially displaced by applying an axial force to the support member 1220.In an exemplary embodiment, the axial displacement of the expansion cone1225 radially expands the expandable tubular member 1235 into intimatecontact with the walls of the wellbore casing 1200.

As illustrated in FIG. 12 d, in an exemplary embodiment, after theexpandable tubular member 1235 has been radially expanded by the axialdisplacement of the expandable expansion cone 1235, the opening 1210 inthe wellbore casing 1200 is sealed off by the radially expanded tubularmember 1235. In this manner, repairs to the wellbore casing 1200 areoptimally provided. More generally, the apparatus 1215 is used to repairor form wellbore casings, pipelines, and structural supports.

Referring to FIGS. 13 a to 13 d, an alternative embodiment of anapparatus and method for coupling an expandable tubular member to apreexisting structure will now be described. Referring to FIG. 13 a, awellbore casing 1300 is positioned within a subterranean formation 1305.The wellbore casing 1300 may be positioned in any orientation from thevertical direction to the horizontal direction. The wellbore casing 1300further includes one or more openings 1310 that may have been the resultof unintentional damage to the wellbore casing 1300, or due to a priorperforation or fracturing operation performed upon the surroundingsubterranean formation 1305. As will be recognized by persons havingordinary skill in the art, the openings 1310 can adversely affect thesubsequent operation and use of the wellbore casing 1300 unless they aresealed off.

In an exemplary embodiment, an apparatus 1315 is utilized to seal offthe openings 1310 in the wellbore casing 1300. More generally, theapparatus 1315 is preferably utilized to form or repair wellborecasings, pipelines, or structural supports.

The apparatus 1315 preferably includes a support member 1320, anexpansion cone 1325, an expandable tubular member 1335, a heater 1340,and one or more sealing members 1345.

The support member 1320 is preferably adapted to be coupled to a surfacelocation. The support member 1320 is further coupled to the expansioncone 1325. The support member 1320 is preferably adapted to conveypressurized fluidic materials and/or electrical current and/orcommunication signals from a surface location to the expansion cone 1325and heater 1340. The support member 1320 may, for example, beconventional commercially available slick wire, braided wire, coiledtubing, or drilling stock material.

The expansion cone 1325 is coupled to the support member 1320. Theexpansion cone 1325 is preferably adapted to radially expand theexpandable tubular member 1335 when the expansion cone 1325 is axiallydisplaced relative to the expandable tubular member 1335. The expansioncone 1325 may be any number of conventional commercially availableexpansion cones.

In an exemplary embodiment, the expansion cone 1325 is further providedsubstantially as disclosed in one or more of the following: (1) U.S.utility patent application Ser. No. 09/454,139, attorney docket no.25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of thefiling date of U.S. provisional patent application No. 60/111,293,attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utilitypatent application Ser. No. 09/510,913, attorney docket no. 25791.7.02,filed on Feb. 23, 2000, which claimed the benefit of the filing date ofU.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3)U.S. utility patent application Ser. No. 09/502,350, attorney docket no.25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of thefiling date of U.S. provisional application No. 60/119,611, attorneydocket no. 25791.8; (4) U.S. utility patent application Ser. No.09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/108,558, attorney docket no. 25791.9, filed on Nov.16, 1998; (5) U.S. provisional patent application No. 60/183,546, filedon Feb. 18, 2000; (6) U.S. utility patent application Ser. No.09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utilitypatent application Ser. No. 09/512,895, attorney docket no. 25791.12.02,filed on Feb. 24, 2000, which claimed the benefit of the filing dates ofU.S. provisional application No. 60/121,841, attorney docket no.25791.12, filed on Feb. 26, 1999 and U.S. provisional application Ser.No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999;(8) U.S. utility application Ser. No. 09/511,941, attorney docket no.25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of thefiling date of U.S. provisional Ser. No. 60/121,907, attorney docket no.25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent applicationSer. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7,2000, which claimed the benefit of the filing date of U.S. provisionalpatent application Ser. No. 60/137,998, attorney docket no. 25791.17,filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No.09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/131,106, attorney docket no. 25791.23, filed on Apr.26, 1999; (11) U.S. provisional application Ser. No. 60/146,203,attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S.provisional application No. 60/143,039, attorney docket no. 25791.26,filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No.60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14)U.S. provisional application Ser. No. 60/159,039, attorney docket no.25791.36, filed on 10/12,1999; (15) U.S. provisional patent applicationNo. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999;and (16) U.S. provisional patent application No. 60/165,228, attorneydocket no. 25791.39, filed on Nov. 12, 1999, the disclosures of whichare incorporated herein by reference.

The expandable tubular member 1335 is removably coupled to the expansioncone 1325. In an exemplary embodiment, the expandable tubular member1335 includes one or more engagement devices 1350 that are adapted tocouple with and penetrate the wellbore casing 1300. In this manner, theexpandable tubular member 1335 is optimally coupled to the wellborecasing 1300. In an exemplary embodiment, the engagement devices 1350include teeth for biting into the surface of the wellbore casing 1300.

In an exemplary embodiment, the expandable tubular member 1335 furtherincludes a lower section 1355, an intermediate section 1360, and anupper section 1365. In an exemplary embodiment, the lower section 1355includes the engagement devices 1350 in order to provide anchoring at anend portion of the expandable tubular member 1335. In an exemplaryembodiment, the wall thickness of the lower and intermediate sections,1355 and 1360, are less than the wall thickness of the upper section1365 in order to optimally facilitate the radial expansion of the lowerand intermediate sections, 1355 and 1360, of the expandable tubularmember 1335.

In an exemplary embodiment, the lower section 1355 of the expandabletubular member 1335 includes one or more shape memory metal inserts1370. In an exemplary embodiment, the inserts 1370 are adapted toradially expand the lower section 1355 of the expandable tubular member1335 into intimate contact with the wellbore casing 1300 when heated bythe heater 1340. The shape memory metal inserts 1370 may be fabricatedfrom any number of conventional commercially available shape memoryalloys such as, for example, NiTi or NiTiNOL using conventional formingprocesses such as, for example, those described in U.S. Pat. Nos.5,312,152, 5,344,506, and 5,718,531, the disclosures of which areincorporated herein by reference. In this manner, the shape memory metalinserts 1370 preferably radially expand the lower section 1355 of theexpandable tubular member 1335 when the inserts 1370 are heated to atemperature above their transformation temperature using the heater1340. In an exemplary embodiment, the transformation temperature of theinserts 1370 ranges from about 250E F to 450E F. In an exemplaryembodiment, the material composition of the lower section 1355 of theexpandable tubular member 1335 is further selected to maximize theradial expansion of the lower section 1355 during the transformationprocess.

In an exemplary embodiment, the inserts 1370 are positioned within oneor more corresponding recesses 1375 provided in the lower section 1355of the expandable tubular member 1335. Alternatively, the inserts 1370are completely contained within the lower section 1355 of the expandabletubular member 1335.

In an exemplary embodiment, the expandable tubular member 1335 isfurther provided substantially as disclosed in one or more of thefollowing: (1) U.S. utility patent application Ser. No. 09/454,139,attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed thebenefit of the filing date of U.S. provisional patent application No.60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S.utility patent application Ser. No. 09/510,913, attorney docket no.25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of thefiling date of U.S. provisional application No. 60/121,702, filed onFeb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350,attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimedthe benefit of the filing date of U.S. provisional application No.60/119,611, attorney docket no. 25791.8; (4) U.S. utility patentapplication Ser. No. 09/440,338, attorney docket no. 25791.9.02, filedon Nov. 15, 1999, which claimed the benefit of the filing date of U.S.provisional application No. 60/108,558, attorney docket no. 25791.9,filed on 11/16.1998; (5) U.S. provisional patent application No.60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent applicationSer. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10,2000, which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utilitypatent application Ser. No. 09/512,895, attorney docket no. 25791.12.02,filed on Feb. 24, 2000, which claimed the benefit of the filing dates ofU.S. provisional application No. 60/121,841, attorney docket no.25791.12, filed on Feb. 26, 1999 and U.S. provisional application Ser.No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999;(8) U.S. utility application Ser. No. 09/511,941, attorney docket no.25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of thefiling date of U.S. provisional Ser. No. 60/121,907, attorney docket no.25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent applicationSer. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7,2000, which claimed the benefit of the filing date of U.S. provisionalpatent application Ser. No. 60/137,998, attorney docket no. 25791.17,filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No.09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/131,106, attorney docket no. 25791.23, filed on Apr.26, 1999; (11) U.S. provisional application Ser. No. 60/146,203,attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S.provisional application No. 60/143,039, attorney docket no. 25791.26,filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No.60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14)U.S. provisional application Ser. No. 60/159,039, attorney docket no.25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patentapplication No. 60/159,033, attorney docket no. 25791.37, filed on Oct.12, 1999; and (16) U.S. provisional patent application No. 60/165,228,attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures ofwhich are incorporated herein by reference.

The heater 1340 is coupled to the support member 1320. The heater 1340is preferably adapted to controllably generate a localized heat sourcefor elevating the temperature of the inserts 1370. In an exemplaryembodiment, the heater 1340 includes a conventional thermostat controlin order to control the operating temperature. The heater 1340 ispreferably controlled by a surface control device in a conventionalmanner.

The sealing members 1345 are preferably coupled to the outer surface ofthe upper portion 1365 of the expandable tubular member 1335. Thesealing members 1345 are preferably adapted to engage and fluidicly sealthe interface between the radially expanded expandable tubular member1335 and the wellbore casing 1300. In an exemplary embodiment, theapparatus 1315 includes a plurality of sealing members 1345. In anexemplary embodiment, the sealing members 1345 surround and isolate theopening 1310.

As illustrated in FIG. 13 a, the apparatus 1315 is preferably positionedwithin the wellbore casing 1300 with the expandable tubular member 1335positioned in opposing relation to the opening 1310. In an exemplaryembodiment, the apparatus 1315 includes a plurality of sealing members1345 that are positioned above and below the opening 1310. In thismanner, the radial expansion of the expandable tubular member 1335optimally fluidicly isolates the opening 1310.

As illustrated in FIG. 13 b, in an exemplary embodiment, the expandabletubular member 1335 of the apparatus 1315 is then anchored to thewellbore casing 1300 by radially expanding the inserts 1370 using theheater 1340. In an exemplary embodiment, the expansion of the inserts1370 causes the lower section 1355 of the expandable tubular member 1335to contact the wellbore casing 1300. In an exemplary embodiment, theengagement devices 1350 are thereby coupled to, and at least partiallypenetrate into, the wellbore casing 1300. In this manner, the lowersection 1355 of the expandable tubular member 1335 is optimally coupledto the wellbore casing 1300.

In an alternative embodiment, a compressible cement and/or epoxy is theninjected into the annular space between the unexpanded portion of thetubular member 1335 and the wellbore casing 1300. The compressiblecement and/or epoxy may then be permitted to at least partially cureprior to the initiation of the radial expansion process. In this manner,an annular structural support and fluidic seal is provided around thetubular member 1335.

As illustrated in FIG. 13 c, the expansion cone 1325 is then axiallydisplaced by applying an axial force to the support member 1320. In anexemplary embodiment, the axial displacement of the expansion cone 1325radially expands the expandable tubular member 1335 into intimatecontact with the walls of the wellbore casing 1300.

As illustrated in FIG. 13 d, in an exemplary embodiment, after theexpandable tubular member 1335 has been completely radially expanded bythe axial displacement of the expansion cone 1335, the opening 1310 inthe wellbore casing 1300 is sealed off by the radially expanded tubularmember 1335. In this manner, repairs to the wellbore casing 1300 areoptimally provided. More generally, the apparatus 1315 is used to repairor form wellbore casings, pipelines, and structural supports.

Referring to FIGS. 14 a to 14 g, an alternative embodiment of anapparatus and method for coupling an expandable tubular member to apreexisting structure will now be described. Referring to FIG. 14 a, awellbore casing 1400 is positioned within a subterranean formation 1405.The wellbore casing 1400 may be positioned in any orientation from thevertical direction to the horizontal direction. The wellbore casing 1400further includes one or more openings 1410 that may have been the resultof unintentional damage to the wellbore casing 1400, or due to a priorperforation or fracturing operation performed upon the surroundingsubterranean formation 1405. As will be recognized by persons havingordinary skill in the art, the openings 1410 can adversely affect thesubsequent operation and use of the wellbore casing 1400 unless they aresealed off.

In an exemplary embodiment, an apparatus 1415 is utilized to seal offthe openings 1410 in the wellbore casing 1400. More generally, theapparatus 1415 is preferably utilized to form or repair wellborecasings, pipelines, or structural supports.

The apparatus 1415 preferably includes a first support member 1420, asecond support member 1425, a coupling 1430, an expandable tubularmember 1435, an expansion cone 1440, a third support member 1445, and apacker 1450.

The first support member 1420 is preferably adapted to be coupled to asurface location. The support member 1420 is further coupled to theexpansion cone 1440. The first support member 1420 is preferably adaptedto convey pressurized fluidic materials and/or electrical current and/orcommunication signals from a surface location to the expansion cone 1440and the packer 1450. The first support member 1420 may, for example, beconventional commercially available slick wire, braided wire, coiledtubing, or drilling stock material.

The second support member 1425 is preferably adapted to be coupled to asurface location. The support member 1425 is further coupled to thecoupling 1430. The first support member 1425 is preferably adapted toconvey pressurized fluidic materials and/or electrical current and/orcommunication signals from a surface location to the coupling 1430. Thesecond support member 1425 may, for example, be conventionalcommercially available slick wire, braided wire, coiled tubing, ordrilling stock material.

The coupling 1430 is coupled to the second support member 1425. Thecoupling 1430 is further preferably removably coupled to the expandabletubular member 1435. The coupling 1430 may be any number of conventionalcommercially available passive or actively controlled coupling devicessuch as, for example, packers or slips. In an exemplary embodiment, thecoupling 1430 is a mechanical slip.

The expandable tubular member 1435 is removably coupled to the coupling1430. In an exemplary embodiment, the expandable tubular member 1435includes one or more engagement devices that are adapted to couple withand penetrate the wellbore casing 1400. In this manner, the expandabletubular member 1435 is optimally coupled to the wellbore casing 1400. Inan exemplary embodiment, the engagement devices include teeth for bitinginto the surface of the wellbore casing 1400. In an exemplaryembodiment, the expandable tubular member 1435 further includes one ormore sealing members on the outside surface of the expandable tubularmember 1435 in order to optimally seal the interface between theexpandable tubular member 1435 and the wellbore casing 1400.

In an exemplary embodiment, the expandable tubular member 1435 isfurther provided substantially as disclosed in one or more of thefollowing: (1) U.S. utility patent application Ser. No. 09/454,139,attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed thebenefit of the filing date of U.S. provisional patent application No.60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S.utility patent application Ser. No. 09/510,913, attorney docket no.25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of thefiling date of U.S. provisional application No. 60/121,702, filed onFeb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350,attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimedthe benefit of the filing date of U.S. provisional application No.60/119,611, attorney docket no. 25791.8; (4) U.S. utility patentapplication Ser. No. 09/440,338, attorney docket no. 25791.9.02, filedon Nov. 15, 1999, which claimed the benefit of the filing date of U.S.provisional application No. 60/108,558, attorney docket no. 25791.9,filed on Nov. 16, 1998; (5) U.S. provisional patent application No.60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent applicationSer. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10,2000, which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utilitypatent application Ser. No. 09/512,895, attorney docket no. 25791.12.02,filed on Feb. 24, 2000, which claimed the benefit of the filing dates ofU.S. provisional application No. 60/121,841, attorney docket no.25791.12, filed on Feb. 26, 1999 and U.S. provisional application Ser.No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999;(8) U.S. utility application Ser. No. 09/511,941, attorney docket no.25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of thefiling date of U.S. provisional Ser. No. 60/121,907, attorney docket no.25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent applicationSer. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7,2000, which claimed the benefit of the filing date of U.S. provisionalpatent application Ser. No. 60/137,998, attorney docket no. 25791.17,filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No.09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/131,106, attorney docket no. 25791.23, filed on Apr.26, 1999; (11) U.S. provisional application Ser. No. 60/146,203,attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S.provisional application No. 60/143,039, attorney docket no. 25791.26,filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No.60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14)U.S. provisional application Ser. No. 60/159,039, attorney docket no.25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patentapplication No. 60/159,033, attorney docket no. 25791.37, filed on Oct.12, 1999; and (16) U.S. provisional patent application No. 60/165,228,attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures ofwhich are incorporated herein by reference.

The expansion cone 1440 is coupled to the first support member 1420 andthe third support member 1445. The expansion cone 1440 is preferablyadapted to radially expand the expandable tubular member 1435 when theexpansion cone 1440 is axially displaced relative to the expandabletubular member 1435.

In an exemplary embodiment, the expansion cone 1440 is providedsubstantially as disclosed in one or more of the following: (1) U.S.utility patent application Ser. No. 09/454,139, attorney docket no.25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of thefiling date of U.S. provisional patent application No. 60/111,293,attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utilitypatent application Ser. No. 09/510,913, attorney docket no. 25791.7.02,filed on Feb. 23, 2000, which claimed the benefit of the filing date ofU.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3)U.S. utility patent application Ser. No. 09/502,350, attorney docket no.25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of thefiling date of U.S. provisional application No. 60/119,611, attorneydocket no. 25791.8; (4) U.S. utility patent application Ser. No.09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/108,558, attorney docket no. 25791.9, filed on Nov.16, 1998; (5) U.S. provisional patent application No. 60/183,546, filedon Feb. 18, 2000; (6) U.S. utility patent application Ser. No.09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utilitypatent application Ser. No. 09/512,895, attorney docket no. 25791.12.02,filed on Feb. 24, 2000, which claimed the benefit of the filing dates ofU.S. provisional application No. 60/121,841, attorney docket no.25791.12, filed on Feb. 26, 1999 and U.S. provisional application Ser.No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999;(8) U.S. utility application Ser. No. 09/511,941, attorney docket no.25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of thefiling date of U.S. provisional Ser. No. 60/121,907, attorney docket no.25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent applicationSer. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7,2000, which claimed the benefit of the filing date of U.S. provisionalpatent application Ser. No. 60/137,998, attorney docket no. 25791.17,filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No.09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/131,106, attorney docket no. 25791.23, filed on Apr.26, 1999; (11) U.S. provisional application Ser. No. 60/146,203,attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S.provisional application No. 60/143,039, attorney docket no. 25791.26,filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No.60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14)U.S. provisional application Ser. No. 60/159,039, attorney docket no.25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patentapplication No. 60/159,033, attorney docket no. 25791.37, filed on Oct.12, 1999; and (16) U.S. provisional patent application No. 60/165,228,attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures ofwhich are incorporated herein by reference.

The third support member 1445 is preferably coupled to the expansioncone 1440 and the packer 1450. The third support member 1445 ispreferably adapted to convey pressurized fluidic materials and/orelectrical current and/or communication signals from a surface locationto the packer 1450. The third support member 1445 may, for example, beconventional commercially available slick wire, braided wire, coiledtubing, or drilling stock material.

The packer 1450 is coupled to the third support member 1445. The packer1450 is further preferably adapted to controllably coupled to thewellbore casing 1400. The packer 1450 may be any number of conventionalcommercially available packer devices. In an alternative embodiment, abladder, slipped cage assembly or hydraulic slips may be substituted forthe packer 1450.

As illustrated in FIG. 14 a, the apparatus 1415 is preferably positionedwithin the wellbore casing 1400 with the bottom of the expandabletubular member 1435 and the top of the expansion cone 1440 positionedproximate the opening 1410.

As illustrated in FIG. 14 b, in an exemplary embodiment, the packer 1450is then anchored to the wellbore casing 1400. In this manner, theexpansion cone 1440 is maintained in a substantially stationaryposition.

As illustrated in FIG. 14 c, in an exemplary embodiment, the expandabletubular member 1435 is then lowered towards the stationary expansioncone 1440. In an exemplary embodiment, as illustrated in FIG. 14 d, thelower end of the expandable tubular member 1435 impacts the expansioncone 1440 and is radially expanded into contact with the wellbore casing1400. In an exemplary embodiment, the lower end of the expandabletubular member 1435 includes one or more engagement devices for engagingthe wellbore casing 1400 in order to optimally couple the end of theexpandable tubular member 1435 to the wellbore casing 1400.

In an alternative embodiment, a compressible cement and/or epoxy is theninjected into the annular space between the unexpanded portion of thetubular member 1435 and the wellbore casing 1400. The compressiblecement and/or epoxy is then permitted to at least partially cure priorto the initiation of the radial expansion process. In this manner, anannular structural support and fluidic seal is provided around thetubular member 1435.

As illustrated in FIG. 14 e, in an exemplary embodiment, the packer 1450is decoupled from the wellbore casing 1400.

As illustrated in FIG. 14 f, in an exemplary embodiment, the expansioncone 1440 is then axially displaced by applying an axial force to thefirst support member 1420. In an exemplary embodiment, the axialdisplacement of the expansion cone 1440 radially expands the expandabletubular member 1435 into intimate contact with the walls of the wellborecasing 1400. In an exemplary embodiment, prior to the initiation of theaxial displacement of the expansion cone 1440, the coupling 1430 isdecoupled from the expandable tubular member 1430.

As illustrated in FIG. 14 g, in an exemplary embodiment, after theexpandable tubular member 1435 has been completely radially expanded bythe axial displacement of the expansion cone 1440, the opening 1410 inthe wellbore casing 1400 is sealed off by the radially expanded tubularmember 1435. In this manner, repairs to the wellbore casing 1400 areoptimally provided. More generally, the apparatus 1415 is used to repairor form wellbore casings, pipelines, and structural supports.

Referring to FIGS. 15 a to 15 d, an alternative embodiment of anapparatus for coupling an expandable tubular member to a preexistingstructure will now be described. Referring to FIG. 15 a, a wellborecasing 1500 is positioned within a subterranean formation 1505. Thewellbore casing 1500 may be positioned in any orientation from thevertical direction to the horizontal direction. The wellbore casing 1500further includes one or more openings 1510 that may have been the resultof unintentional damage to the wellbore casing 1500, or due to a priorperforation or fracturing operation performed upon the surroundingsubterranean formation 1505. As will be recognized by persons havingordinary skill in the art, the openings 1510 can adversely affect thesubsequent operation and use of the wellbore casing 1500 unless they aresealed off.

In an exemplary embodiment, an apparatus 1515 is utilized to seal offthe openings 1510 in the wellbore casing 1500. More generally, theapparatus 1515 is preferably utilized to form or repair wellborecasings, pipelines, or structural supports.

The apparatus 1515 preferably includes a support member 1520, anexpandable tubular member 1525, an expansion cone 1530, a coupling 1535,a resilient anchor 1540, and one or more seals 1545.

The support member 1520 is preferably adapted to be coupled to a surfacelocation. The support member 1520 is further coupled to the expansioncone 1530. The support member 1520 is preferably adapted to conveypressurized fluidic materials and/or electrical current and/orcommunication signals from a surface location to the resilient anchor1540. The support member 1520 may, for example, be conventionalcommercially available slick wire, braided wire, coiled tubing, ordrilling stock material.

The expandable tubular member 1525 is removably coupled to the expansioncone 1530. In an exemplary embodiment, the expandable tubular member1525 includes one or more engagement devices that are adapted to couplewith and penetrate the wellbore casing 1500. In this manner, theexpandable tubular member 1525 is optimally coupled to the wellborecasing 1500. In an exemplary embodiment, the engagement devices includeteeth for biting into the surface of the wellbore casing 1500. In anexemplary embodiment, the expandable tubular member 1525 furtherincludes one or more sealing members 1545 on the outside surface of theexpandable tubular member 1525 in order to optimally seal the interfacebetween the expandable tubular member 1525 and the wellbore casing 1500.

In an exemplary embodiment, the expandable tubular member 1525 includesa lower section 1550, an intermediate section 1555, and an upper section1560. In an exemplary embodiment, the wall thicknesses of the lower andintermediate sections, 1550 and 1555, are less than the wall thicknessof the upper section 1560 in order to optimally facilitate the radialexpansion of the expandable tubular member 1525. In an exemplaryembodiment, the sealing members 1545 are provided on the outside surfaceof the upper section 1560 of the expandable tubular member 1525. In anexemplary embodiment, the resilient anchor 1540 is coupled to the lowersection 1550 of the expandable tubular member 1525 in order to optimallyanchor the expandable tubular member 1525 to the wellbore casing 1500.

In an exemplary embodiment, the expandable tubular member 1525 isfurther provided substantially as disclosed in one or more of thefollowing: (1) U.S. utility patent application Ser. No. 09/454,139,attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed thebenefit of the filing date of U.S. provisional patent application No.60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S.utility patent application Ser. No. 09/510,913, attorney docket no.25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of thefiling date of U.S. provisional application No. 60/121,702, filed onFeb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350,attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimedthe benefit of the filing date of U.S. provisional application No.60/119,611, attorney docket no. 25791.8; (4) U.S. utility patentapplication Ser. No. 09/440,338, attorney docket no. 25791.9.02, filedon Nov. 15, 1999, which claimed the benefit of the filing date of U.S.provisional application No. 60/108,558, attorney docket no. 25791.9,filed on Nov. 16, 1998; (5) U.S. provisional patent application No.60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent applicationSer. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10,2000, which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utilitypatent. application Ser. No. 09/512,895, attorney docket no.25791.12.02, filed on Feb. 24, 2000, which claimed the benefit of thefiling dates of U.S. provisional application No. 60/121,841, attorneydocket no. 25791.12, filed on Feb. 26, 1999 and U.S. provisionalapplication Ser. No. 60/154,047, attorney docket no. 25791.29, filed onSep. 16, 1999; (8) U.S. utility application Ser. No. 09/511,941,attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claimedthe benefit of the filing date of U.S. provisional Ser. No. 60/121,907,attorney docket no. 25791.16, filed on Feb. 26, 1999; (9) U.S. utilitypatent application Ser. No. 09/588,946, attorney docket no. 25791.17.02,filed on Jun. 7, 2000, which claimed the benefit of the filing date ofU.S. provisional patent application Ser. No. 60/137,998, attorney docketno. 25791.17, filed on Jun. 7, 1999; (10) U.S. utility patentapplication Ser. No. 09/559,122, attorney docket no. 25791.23.02, filedon Apr. 26, 2000, which claimed the benefit of the filing date of U.S.provisional application No. 60/131,106, attorney docket no. 25791.23,filed on Apr. 26, 1999; (11) U.S. provisional application Ser. No.60/146,203, attorney docket no. 25791.25, filed on Jul. 29, 1999; (12)U.S. provisional application No. 60/143,039, attorney docket no.25791.26, filed on Jul. 9, 1999; (13) U.S. provisional patentapplication Ser. No. 60/162,671, attorney docket no. 25791.27, filed onNov. 1, 1999; (14) U.S. provisional application Ser. No. 60/159,039,attorney docket no. 25791.36, filed on Oct. 12, 1999; (15) U.S.provisional patent application No. 60/159,033, attorney docket no.25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patentapplication No. 60/165,228, attorney docket no. 25791.39, filed on Nov.12, 1999, the disclosures of which are incorporated herein by reference.

The expansion cone 1530 is coupled to the support member 1520 and thecoupling 1535. The expansion cone 1530 is preferably adapted to radiallyexpand the expandable tubular member 1525 when the expansion cone 1530is axially displaced relative to the expandable tubular member 1525. Theexpansion cone 1530 may be any number of conventional commerciallyavailable expansion cones.

In an exemplary embodiment, the expansion cone 1530 is providedsubstantially as disclosed in one or more of the following: (1) U.S.utility patent application Ser. No. 09/454,139, attorney docket no.25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of thefiling date of U.S. provisional patent application No. 60/111,293,attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utilitypatent application Ser. No. 09/510,913, attorney docket no. 25791.7.02,filed on Feb. 23, 2000, which claimed the benefit of the filing date ofU.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3)U.S. utility patent application Ser. No. 09/502,350, attorney docket no.25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of thefiling date of U.S. provisional application No. 60/119,611, attorneydocket no. 25791.8; (4) U.S. utility patent application Ser. No.09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/108,558, attorney docket no. 25791.9, filed on Nov.16, 1998; (5) U.S. provisional patent application No. 60/183,546, filedon Feb. 18, 2000; (6) U.S. utility patent application Ser. No.09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utilitypatent application Ser. No. 09/512,895, attorney docket no. 25791.12.02,filed on Feb. 24, 2000, which claimed the benefit of the filing dates ofU.S. provisional application No. 60/121,841, attorney docket no.25791.12, filed on Feb. 26, 1999 and U.S. provisional application Ser.No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999;(8) U.S. utility application Ser. No. 09/511,941, attorney docket no.25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of thefiling date of U.S. provisional Ser. No. 60/121,907, attorney docket no.25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent applicationSer. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7,2000, which claimed the benefit of the filing date of U.S. provisionalpatent application Ser. No. 60/137,998, attorney docket no. 25791.17,filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No.09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/131,106, attorney docket no. 25791.23, filed on Apr.26, 1999; (11) U.S. provisional application Ser. No. 60/146,203,attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S.provisional application No. 60/143,039, attorney docket no. 25791.26,filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No.60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14)U.S. provisional application Ser. No. 60/159,039, attorney docket no.25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patentapplication No. 60/159,033, attorney docket no. 25791.37, filed on Oct.12, 1999; and (16) U.S. provisional patent application No. 60/165,228,attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures ofwhich are incorporated herein by reference.

The coupling 1535 is preferably coupled to the support member 1520, theexpansion cone 1530 and the resilient anchor 1540. The coupling 1535 ispreferably adapted to convey pressurized fluidic materials and/orelectrical current and/or communication signals from a surface locationto the resilient anchor 1535. The coupling 1535 may, for example, beconventional commercially available slick wire, braided wire, coiledtubing, or drilling stock material. In an exemplary embodiment, thecoupling 1535 is decoupled from the resilient anchor 1540 uponinitiating the axial displacement of the expansion cone 1530.

The resilient anchor 1540 is preferably coupled to the lower section1550 of the expandable tubular member 1525 and the coupling 1535. Theresilient anchor 1540 is further preferably adapted to be controllablycoupled to the wellbore casing 1500.

Referring to FIGS. 16 a and 16 b, in an exemplary embodiment, theresilient anchor 1540 includes one or more coiled resilient members 1600and corresponding releasable coupling devices 1605. In an exemplaryembodiment, the resilient anchor 1540 is maintained in a compressedelastic position that is controllably released thereby causing theresilient anchor 1540 to expand in size thereby releasing the elasticenergy stored within the resilient anchor 1540. As illustrated in FIG.16 b, in an exemplary embodiment, when the coupling device 1605 isreleased, the coiled resilient member 1600 at least partially uncoils inthe outward radial direction. In an exemplary embodiment, at least aportion of the coiled member 1600 is coupled to the lower section 1550of the expandable tubular member 1525. In an exemplary embodiment, theuncoiled member 1600 thereby couples the lower section 1550 of theexpandable tubular member 1525 to the wellbore casing 1500.

The coiled member 1600 may be fabricated from any number of conventionalcommercially available resilient materials. In an exemplary embodiment,the coiled member 1600 is fabricated from a resilient material such as,for example, spring steel. In an exemplary embodiment, the coiled member1600 is fabricated from memory metals in order to optimally providecontrol of shapes and stresses.

In an exemplary embodiment, the releasable coupling device 1605maintains the coiled member 1600 is a coiled position until the device1605 is released. The releasable coupling device 1605 may be any numberof conventional commercially available releasable coupling devices suchas, for example, an explosive bolt.

The resilient anchor 1540 may be positioned in any desired orientation.In an exemplary embodiment, the resilient anchor 1540 is positioned toapply the maximum normal force to the walls of the wellbore casing 1500after releasing the resilient anchor 1540.

In an alternate embodiment, as illustrated in FIGS. 17 a and 17 b, theresilient anchor 1540 includes a tubular member 1700, one or moreresilient anchoring members 1705, one or more corresponding rigidattachments 1710, and one more corresponding releasable attachments1715. In an exemplary embodiment, the resilient anchoring members 1705are maintained in compressed elastic condition by the correspondingrigid and releasable attachments, 1710 and 1715. In an exemplaryembodiment, when the corresponding releasable attachment 1715 isreleased, the corresponding resilient anchoring member 1705 expands,releasing the stored elastic energy, away from the tubular member 1700.

As illustrated in FIG. 17 a, one end of each resilient anchoring member1705 is rigidly attached to the outside surface of the tubular member1700 by a corresponding rigid attachment 1710. The other end of eachresilient anchoring member 1705 is removably attached to the outsidesurface of the tubular member 1700 by a corresponding releasableattachment 1715. As illustrated in FIG. 17 b, in an exemplaryembodiment, releasing the releasable attachment 1715 permits theresilient energy stored in the resilient anchoring member 1705 to bereleased thereby causing the resilient anchoring member 1705 to swingradially outward from the tubular member 1700.

The tubular member 1700 may be fabricated from any number ofconventional materials.

The resilient anchoring members 1705 may be fabricated from any numberof resilient materials. In an exemplary embodiment, the resilientanchoring members 1705 are fabricated from memory metal in order tooptimally provide control of shapes and stresses.

The rigid attachments 1710 may be fabricated from any number ofconventional commercially available materials. In an exemplaryembodiment, the rigid attachments 1710 are fabricated from 4140 steel inorder to optimally provide high strength.

The releasable attachments 1715 may be fabricated from any number ofconventional commercially available devices such as, for example,explosive bolts.

In another alternative embodiment, as illustrated in FIGS. 18 a and 18b, the resilient anchor 1540 includes a tubular member 1800, one or moreanchoring devices 1805, one or more resilient members 1810, and one ormore release devices 1815. In an exemplary embodiment, the anchoringdevices 1805 and resilient members 1810 are maintained in a compressedelastic position by the release devices 1815. As illustrated in FIG. 18b, in an exemplary embodiment, when the release devices 1815 areremoved, the anchoring devices 1805 and resilient members 1810 arepermitted to expand outwardly in the radial direction.

The tubular member 1800 preferably includes one or more openings 1820for containing the release devices 1815 and for permitting the anchoringdevices 1805 to pass through. The tubular member 1800 may be fabricatedfrom any number of conventional commercially available materials. In anexemplary embodiment, the tubular member 1800 is fabricated from 4140steel in order to optimally provide high strength.

The anchoring devices 1805 are housed within the tubular member 1800.The anchoring devices 1805 are preferably adapted to at least partiallyextend through the corresponding openings 1820 in the tubular member1800. The anchoring devices 1805 are preferably adapted to couple to,and at least partially penetrate, the surface of the wellbore 1500. Theanchoring devices 1805 may be fabricated from any number of durable hardmaterials such as, for example, tungsten carbide, machine tool steel, orhard faced steel. In an exemplary embodiment, the anchoring devices 1805are fabricated from machine tool steel in order to optimally providehigh strength, hardness, and fracture toughness.

The resilient members 1810 are coupled to the inside surface of thetubular member 1800. The resilient members 1810 are preferably adaptedto apply a radial force upon the corresponding anchoring devices 1805.In an exemplary embodiment, when the release devices 1815 release theanchoring devices 1805, the resilient members 1810 are preferablyadapted to force the anchoring devices at least partially through thecorresponding openings 1820 into contact with, to at least partiallypenetrate, the wellbore casing 1500.

The release devices 1815 are positioned within and coupled to theopenings 1820 in the tubular member 1800. The release devices 1815 arepreferably adapted to hold the corresponding anchoring devices 1805within the tubular member 1800 until released by a control signalprovided from a surface, or other, location. The release devices 1815may be any number of conventional commercially available releasedevices. In an exemplary embodiment, the release devices 1815 arepressure activated in order to optimally provide ease of operation.

As illustrated in FIG. 15 a, the apparatus 1515 is preferably positionedwithin the wellbore casing 1500 with the expandable tubular member 1525positioned in opposing relation to the opening 1510.

As illustrated in FIG. 15 b, in an exemplary embodiment, the resilientanchor 1540 is then anchored to the wellbore casing 1500. In thismanner, the lower section 1550 of the expandable tubular member 1525 isanchored to the wellbore casing 1500. In an exemplary embodiment, theresilient anchor 1540 is anchored by a control and/or electrical powersignal transmitted from a surface location.

In an alternative embodiment, a compressible cement and/or epoxy is theninjected into the annular space between the unexpanded portion of thetubular member 1525 and the wellbore casing 1500. The compressiblecement and/or epoxy is then permitted to at least partially cure priorto the initiation of the radial expansion process. In this manner, anannular structural support and fluidic seal is provided around thetubular member 1525.

As illustrated in FIG. 15 c, in an exemplary embodiment, the expansioncone 1530 is then axially displaced by applying an axial force to thesupport member 1520. In an exemplary embodiment, the axial displacementof the expansion cone 1530 radially expands the expandable tubularmember 1525 into intimate contact with the walls of the wellbore casing1500.

As illustrated in FIG. 15 d, in an exemplary embodiment, after theexpandable tubular member 1525 has been completely radially expanded bythe axial displacement of the expansion cone 1530, the opening 1510 inthe wellbore casing 1500 is sealed off by the radially expanded tubularmember 1525. In this manner, repairs to the wellbore casing 1500 areoptimally provided. More generally, the apparatus 1515 is used to repairor form wellbore casings, pipelines, and structural supports.

Referring to FIGS. 19 a, 19 b and 19 c, an alternative embodiment of anexpandable tubular member 1900 for use in the apparatus 1515 will now bedescribed. In an exemplary embodiment, the expandable tubular member1900 includes a tubular body 1905, one or more resilient panels 1910,one or more corresponding engagement members 1915, and a release member1920. In an exemplary embodiment, the resilient panels 1910 are adaptedto expand in the radial direction after being released by the releasemember 1920. In this manner, the expandable tubular member 1900 isanchored to a preexisting structure such as, for example, a wellborecasing, an open hole wellbore section, a pipeline, or a structuralsupport.

The tubular member 1905 is coupled to the resilient panels 1910. Thetubular member 1905 may be any number of conventional commerciallyavailable expandable tubular members. In an exemplary embodiment, thetubular member 1905 is an expandable casing in order to optimallyprovide high strength.

The resilient panels 1910 are coupled to the tubular member 1905. Theresilient panels 1910 are further releasably coupled to the releasemember 1920. The resilient panels 1910 are preferably adapted to housethe expansion cone 1530. The resilient panels 1910 are preferablyadapted to extend to the position 1925 upon being released by therelease member 1920. In an exemplary embodiment, the resilient panels1910 are coupled to the tubular member 1905 by welding in order tooptimally provide high strength. The resilient panels 1910 may befabricated from any number of conventional commercially availableresilient materials. In an exemplary embodiment, the resilient panels1910 are fabricated from spring steel in order to optimally storeelastic radially directed energy.

The engagement members 1915 are coupled to corresponding resilientpanels. The engagement members 1915 are preferably adapted to engage,and at least partially penetrate, the wellbore casing 1500, or otherpreexisting structure.

The release member 1920 is releasably coupled to the resilient panels1910. The release member 1920 is preferably adapted to controllablyrelease the resilient panels 1910 from their initial strained positionsin order to permit the resilient panels 1910 to expand to their expandedpositions 1925. In an exemplary embodiment, the release member 1920 isreleasably coupled to the coupling 1535. In this manner, electricaland/or control and/or hydraulic signals are communicated to and/or fromthe release member 1920. The release member 1920 may be any number ofconventional commercially available release devices.

Referring to FIGS. 20 a to 20 d, an alternative embodiment of anapparatus and method for coupling an expandable tubular member to apreexisting structure will now be described. Referring to FIG. 20 a, awellbore casing 2000 is positioned within a subterranean formation 2005.The wellbore casing 2000 may be positioned in any orientation from thevertical direction to the horizontal direction. The wellbore casing 2000further includes one or more openings 2010 that may have been the resultof unintentional damage to the wellbore casing 2000, or due to a priorperforation or fracturing operation performed upon the surroundingsubterranean formation 2005. As will be recognized by persons havingordinary skill in the art, the openings 2010 can adversely affect thesubsequent operation and use of the wellbore casing 2000 unless they aresealed off.

In an exemplary embodiment, an apparatus 2015 is utilized to seal offthe openings 2010 in the wellbore casing 2000. More generally, theapparatus 2015 is preferably utilized to form or repair wellborecasings, pipelines, or structural supports.

The apparatus 2015 preferably includes a support member 2020, anexpandable tubular member 2025, an expansion cone 2030, a coupling 2035,a resilient anchor 2040, and one or more seals 2045.

The support member 2020 is preferably adapted to be coupled to a surfacelocation. The support member 2020 is further coupled to the expansioncone 2030. The support member 2020 is preferably adapted to conveypressurized fluidic materials and/or electrical current and/orcommunication signals from a surface location to the anchor 2040. Thesupport member 2020 may, for example, be conventional commerciallyavailable slick wire, braided wire, coiled tubing, or drilling stockmaterial.

The expandable tubular member 2025 is removably coupled to the expansioncone 2030. In an exemplary embodiment, the expandable tubular member2025 includes one or more engagement devices that are adapted to couplewith and penetrate the wellbore casing 2000. In this manner, theexpandable tubular member 2025 is optimally coupled to the wellborecasing 2000. In an exemplary embodiment, the engagement devices includeteeth for biting into the surface of the wellbore casing 2000. In anexemplary embodiment, the expandable tubular member 2025 furtherincludes one or more sealing members 2045 on the outside surface of theexpandable tubular member 2025 in order to optimally seal the interfacebetween the expandable tubular member 2025 and the wellbore casing 2000.

In an exemplary embodiment, the expandable tubular member 2025 includesa lower section 2050, an intermediate section 2055, and an upper section2060. In an exemplary embodiment, the wall thicknesses of the lower andintermediate sections, 2050 and 2055, are less than the wall thicknessof the upper section 2060 in order to optimally facilitate the radialexpansion of the expandable tubular member 2025. In an exemplaryembodiment, the sealing members 2045 are provided on the outside surfaceof the upper section 2060 of the expandable tubular member 2025. In anexemplary embodiment, the resilient anchor 2040 is coupled to the lowersection 2050 of the expandable tubular member 2025 in order to optimallyanchor the expandable tubular member 2025 to the wellbore casing 2000.

In an exemplary embodiment, the expandable tubular member 2025 isfurther provided substantially as disclosed in one or more of thefollowing: (1) U.S. utility patent application Ser. No. 09/454,139,attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed thebenefit of the filing date of U.S. provisional patent application No.60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S.utility patent application Ser. No. 09/510,913, attorney docket no.25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of thefiling date of U.S. provisional application No. 60/121,702, filed onFeb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350,attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimedthe benefit of the filing date of U.S. provisional application No.60/119,611, attorney docket no. 25791.8; (4) U.S. utility patentapplication Ser. No. 09/440,338, attorney docket no. 25791.9.02, filedon Nov. 15, 1999, which claimed the benefit of the filing date of U.S.provisional application No. 60/108,558, attorney docket no. 25791.9,filed on Nov. 16, 1998; (5) U.S. provisional patent application No.60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent applicationSer. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10,2000, which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utilitypatent application Ser. No. 09/512,895, attorney docket no. 25791.12.02,filed on Feb. 24, 2000, which claimed the benefit of the filing dates ofU.S. provisional application No. 60/121,841, attorney docket no.25791.12, filed on Feb. 26, 1999 and U.S. provisional application Ser.No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999;(8) U.S. utility application Ser. No. 09/511,941, attorney docket no.25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of thefiling date of U.S. provisional Ser. No. 60/121,907, attorney docket no.25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent applicationSer. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7,2000, which claimed the benefit of the filing date of U.S. provisionalpatent application Ser. No. 60/137,998, attorney docket no. 25791.17,filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No.09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/131,106, attorney docket no. 25791.23, filed on Apr.26, 1999; (11) U.S. provisional application Ser. No. 60/146,203,attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S.provisional application No. 60/143,039, attorney docket no. 25791.26,filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No.60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14)U.S. provisional application Ser. No. 60/159,039, attorney docket no.25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patentapplication No. 60/159,033, attorney docket no. 25791.37, filed on Oct.12, 1999; and (16) U.S. provisional patent application No. 60/165,228,attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures ofwhich are incorporated herein by reference.

The expansion cone 2030 is preferably coupled to the support member 2020and the coupling 2035. The expansion cone 2030 is preferably adapted toradially expand the expandable tubular member 2025 when the expansioncone 2030 is axially displaced relative to the expandable tubular member2025.

In an exemplary embodiment, the expansion cone 2030 is providedsubstantially as disclosed in one or more of the following: (1) U.S.utility patent application Ser. No. 09/454,139, attorney docket no.25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of thefiling date of U.S. provisional patent application No. 60/111,293,attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utilitypatent application Ser. No. 09/510,913, attorney docket no. 25791.7.02,filed on Feb. 23, 2000, which claimed the benefit of the filing date ofU.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3)U.S. utility patent application Ser. No. 09/502,350, attorney docket no.25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of thefiling date of U.S. provisional application No. 60/119,611, attorneydocket no. 25791.8; (4) U.S. utility patent application Ser. No.09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/108,558, attorney docket no. 25791.9, filed on Nov.16, 1998; (5) U.S. provisional patent application No. 60/183,546, filedon Feb. 18, 2000; (6) U.S. utility patent application Ser. No.09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utilitypatent application Ser. No. 09/512,895, attorney docket no. 25791.12.02,filed on Feb. 24, 2000, which claimed the benefit of the filing dates ofU.S. provisional application No. 60/121,841, attorney docket no.25791.12, filed on Feb. 26, 1999 and U.S. provisional application Ser.No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999;(8) U.S. utility application Ser. No. 09/511,941, attorney docket no.25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of thefiling date of U.S. provisional Ser. No. 60/121,907, attorney docket no.25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent applicationSer. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7,2000, which claimed the benefit of the filing date of U.S. provisionalpatent application Ser. No. 60/137,998, attorney docket no. 25791.17,filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No.09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/131,106, attorney docket no. 25791.23, filed on Apr.26, 1999; (11) U.S. provisional application Ser. No. 60/146,203,attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S.provisional application No. 60/143,039, attorney docket no. 25791.26,filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No.60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14)U.S. provisional application Ser. No. 60/159,039, attorney docket no.25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patentapplication No. 60/159,033, attorney docket no. 25791.37, filed on Oct.12, 1999; and (16) U.S. provisional patent application No. 60/165,228,attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures ofwhich are incorporated herein by reference.

The coupling 2035 is preferably coupled to the support member 2020, theexpansion cone 2030, and the anchor 2040. The coupling 2035 ispreferably adapted to convey pressurized fluidic materials and/orelectrical current and/or communication signals from a surface locationto the anchor 2035. The coupling 2035 may, for example, be conventionalcommercially available slick wire, braided wire, coiled tubing, ordrilling stock material. In an exemplary embodiment, the coupling 2035is decoupled from the anchor 2040 upon initiating the axial displacementof the expansion cone 2030.

The anchor 2040 is preferably coupled to the lower section 2050 of theexpandable tubular member 2025 and the coupling 2035. The anchor 2040 isfurther preferably adapted to be controllably coupled to the wellborecasing 2000.

Referring to FIGS. 21 a and 21 b, in an exemplary embodiment, the anchor2040 includes a housing 2100, one or more spikes 2105, and one or morecorresponding actuators 2110. In an exemplary embodiment, the spikes2105 are outwardly extended by the corresponding actuators 2110. In analternative embodiment, the spikes 2105 are outwardly actuated bydisplacing the apparatus 2015 upwardly. In another alternativeembodiment, the spikes 2105 are outwardly extended by placing a quantityof fluidic material onto the spikes 2105.

The housing 2100 is coupled to the lower section 2050 of the expandabletubular member 2025, the spikes 2105, and the actuators 2110. Thehousing 2100 is further preferably coupled to the coupling 2035. In anexemplary embodiment, the housing 2100 is adapted to convey electrical,communication, and/or hydraulic signals from the coupling 2035 to theactuators 2110.

The spikes 2105 are preferably movably coupled to the housing 2100 andthe corresponding actuators 2110. The spikes 2105 are preferably adaptedto pivot relative to the housing 2100. The spikes 2105 are furtherpreferably adapted to extend outwardly in a radial direction to engage,and at least partially penetrate, the wellbore casing 2000, or otherpreexisting structure such as, for example, the wellbore. Each of thespikes 2105 further preferably include a concave upwardly facing surface2115. In an exemplary embodiment, the placement of a quantity of fluidicmaterial such as, for example, a barite plug or a flex plug, onto thesurfaces 2115 causes the spikes 2105 to pivot outwardly away from thehousing 2100 to engage the wellbore casing 2000, or other preexistingstructure such as, for example, the wellbore. Alternatively, the upwarddisplacement of the apparatus 2015 causes the spikes 2105 to pivotoutwardly away from the housing 2100 to engage the wellbore casing 2000,or other preexisting structure such as, for example, the wellbore.

The actuators 2110 are preferably coupled to the housing 2100 and thecorresponding spikes 2105. The actuators 2110 are preferably adapted toapply a force to the corresponding spikes 2105 sufficient to pivot thecorresponding spikes 2105 outwardly and away from the housing 2100. Theactuators 2110 may be any number of conventional commercially availableactuators such as, for example, a spring, an electric or hydraulicmotor, a hydraulic piston/cylinder. In an exemplary embodiment, theactuators 2100 are hydraulic pistons in order to optimally provide easeof operation. In an alternative embodiment, the actuators 2110 areomitted and the spikes are pivotally coupled to the housing 2100.

Referring to FIGS. 22 a, 22 b, and 22 c, in an alternative embodiment,the anchor 2040 includes the housing 2100, one or more petal baskets2205, and one or more corresponding actuators 2110. In an exemplaryembodiment, the petal baskets 2205 are outwardly extended by thecorresponding actuators 2110. In an alternative embodiment, the petalbaskets 2205 are outwardly actuated by displacing the apparatus 2015upwardly. In another alternative embodiment, the petal baskets 2205 areoutwardly extended by placing a quantity of fluidic material onto thepetal baskets 2205.

The housing 2100 is coupled to the lower section 2050 of the expandabletubular member 2025, the petal baskets 2205, and the actuators 2110.

The petal baskets 2205 are preferably movably coupled to the housing2100 and the corresponding actuators 2110. The petal baskets 2205 arepreferably adapted to pivot relative to the housing 2100. The petalbaskets 2205 are further preferably adapted to extend outwardly in aradial direction to engage, and at least partially penetrate, thewellbore casing 2000, or other preexisting structure. As illustrated inFIG. 22 c, each of the petal baskets 2205 further preferably include aconcave upwardly facing surface 2215. In an exemplary embodiment, theplacement of a quantity of fluidic material such as, for example, abarite plug or a flex plug, onto the surfaces 2215 causes the petalbaskets 2205 to pivot outwardly away from the housing 2100 to engage thewellbore casing 2000, or other preexisting structure. Alternatively, theweight of the fluidic materials placed onto the petal baskets 2205 issufficient to anchor the expandable tubular member 2025. Alternatively,the upward displacement of the apparatus 2015 causes the petal baskets2205 to pivot outwardly away from the housing 2100 to engage thewellbore casing 2000, or other preexisting structure.

The actuators 2110 are preferably coupled to the housing 2100 and thecorresponding petal baskets 2205. The actuators 2110 are preferablyadapted to apply a force to the corresponding petal baskets 2205sufficient to pivot the corresponding petal baskets 2205 outwardly andaway from the housing 2100. In an alternative embodiment, the actuators2110 are omitted and the petal baskets are pivotally coupled to thehousing 2100.

In an alternative embodiment, the anchor 2040 includes one or morespikes 2105 and one or more petal baskets 2205.

As illustrated in FIG. 20 a, the apparatus 2015 is preferably positionedwithin the wellbore casing 2000 with the expandable tubular member 2025positioned in opposing relation to the opening 2010.

As illustrated in FIG. 20 b, in an exemplary embodiment, the anchor 2040is then anchored to the wellbore casing 2000. In this manner, the lowersection 2050 of the expandable tubular member 2025 is anchored to thewellbore casing 2000 or the wellbore casing. In an exemplary embodiment,the anchor 2040 is anchored by a control and/or electrical power signaltransmitted from a surface location to the actuators 2110 of the anchor2040. In an alternative embodiment, the anchor 2040 is anchored to thewellbore casing 2000 by upwardly displacing the apparatus 2015. In analternative embodiment, the anchor 2040 is anchored to the wellborecasing 2000 by placing a quantity of a fluidic material such, forexample, a barite plug or a flex plug, onto the spikes 2105 or petalbaskets 2205 of the anchor 2040. In an alternative embodiment, theanchor 2040 is omitted, and the apparatus 2015 is anchored by placing aquantity of a fluidic material such, for example, a barite plug or aflex plug, onto at least the lower and/or the intermediate sections,2050 and 2055, of the expandable tubular member 2025.

In an alternative embodiment, a compressible cement and/or epoxy is theninjected into the annular space between the unexpanded portion of thetubular member 2025 and the wellbore casing 2000. The compressiblecement and/or epoxy is then permitted to at least partially cure priorto the initiation of the radial expansion process. In this manner, anannular structural support and fluidic seal is provided around thetubular member 2025.

As illustrated in FIG. 20 c, in an exemplary embodiment, the expansioncone 2030 is then axially displaced by applying an axial force to thesupport member 2020. In an exemplary embodiment, the axial displacementof the expansion cone 2030 radially expands the expandable tubularmember 2025 into intimate contact with the walls of the wellbore casing2000.

As illustrated in FIG. 20 d, in an exemplary embodiment, after theexpandable tubular member 2025 has been completely radially expanded bythe axial displacement of the expansion cone 2030, the opening 2010 inthe wellbore casing 2000 is sealed off by the radially expanded tubularmember 1435. In this manner, repairs to the wellbore casing 2000 areoptimally provided. More generally, the apparatus 2015 is used to repairor form wellbore casings, pipelines, and structural supports.

Referring to FIGS. 23 a to 23 e, an alternative embodiment of anapparatus and method for coupling an expandable tubular member to apreexisting structure will now be described. Referring to FIG. 23 a, awellbore casing 2300 and an open hole wellbore section 2305 arepositioned within a subterranean formation 2310. The wellbore casing2300 and the open hole wellbore section 2305 may be positioned in anyorientation from the vertical direction to the horizontal direction.

In an exemplary embodiment, an apparatus 2320 is utilized to form a newsection of wellbore casing within the open hole wellbore section 2305.More generally, the apparatus 2320 is preferably utilized to form orrepair wellbore casings, pipelines, or structural supports.

The apparatus 2320 preferably includes a support member 2325, anexpandable tubular member 2330, an expansion cone 2335, one or moreupper sealing members 2340, and one or more sealing members 2345.

The support member 2325 is preferably adapted to be coupled to a surfacelocation. The support member 2325 is further coupled to the expansioncone 2335. The support member 2325 may, for example, be conventionalcommercially available slick wire, braided wire, coiled tubing, ordrilling stock material.

The expandable tubular member 2330 is removably coupled to the expansioncone 2335. In an exemplary embodiment, the expandable tubular member2025 further includes one or more upper and lower sealing members, 2340and 2345, on the outside surface of the expandable tubular member 2330in order to optimally seal the interface between the expandable tubularmember 2330 and the wellbore casing 2300 and the open hole wellboresection 2305.

In an exemplary embodiment, the expandable tubular member 2025 furtherincludes a lower section 2350, an intermediate section 2355, and anupper section 2360. In an exemplary embodiment, the wall thicknesses ofthe lower and intermediate sections, 2350 and 2355, are less than thewall thickness of the upper section 2360 in order to optimallyfacilitate the radial expansion of the expandable tubular member 2330.In an exemplary embodiment, the lower section 2350 of the expandabletubular member 2330 includes one or more slots 2365 adapted to permit afluidic sealing material to penetrate the lower section 2350.

In an exemplary embodiment, the expandable tubular member 2330 isfurther provided substantially as disclosed in one or more of thefollowing: (1) U.S. utility patent application Ser. No. 09/454,139,attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed thebenefit of the filing date of U.S. provisional patent application No.60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S.utility patent application Ser. No. 09/510,913, attorney docket no.25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of thefiling date of U.S. provisional application No. 60/121,702, filed onFeb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350,attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimedthe benefit of the filing date of U.S. provisional application No.60/119,611, attorney docket no. 25791.8; (4) U.S. utility patentapplication Ser. No. 09/440,338, attorney docket no. 25791.9.02, filedon Nov. 15, 1999, which claimed the benefit of the filing date of U.S.provisional application No. 60/108,558, attorney docket no. 25791.9,filed on Nov. 16, 1998; (5) U.S. provisional patent application No.60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent applicationSer. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10,2000, which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utilitypatent application Ser. No. 09/512,895, attorney docket no. 25791.12.02,filed on Feb. 24, 2000, which claimed the benefit of the filing dates ofU.S. provisional application No. 60/121,841, attorney docket no.25791.12, filed on Feb. 26, 1999 and U.S. provisional application Ser.No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999;(8) U.S. utility application Ser. No. 09/511,941, attorney docket no.25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of thefiling date of U.S. provisional Ser. No. 60/121,907, attorney docket no.25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent applicationSer. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7,2000, which claimed the benefit of the filing date of U.S. provisionalpatent application Ser. No. 60/137,998, attorney docket no. 25791.17,filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No.09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/131,106, attorney docket no. 25791.23, filed on Apr.26, 1999; (11) U.S. provisional application Ser. No. 60/146,203,attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S.provisional application No. 60/143,039, attorney docket no. 25791.26,filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No.60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14)U.S. provisional application Ser. No. 60/159,039, attorney docket no.25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patentapplication No. 60/159,033, attorney docket no. 25791.37, filed on Oct.12, 1999; and (16) U.S. provisional patent application No. 60/165,228,attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures ofwhich are incorporated herein by reference.

The expansion cone 2335 is preferably coupled to the support member2325. The expansion cone 2335 is further preferably removably coupled tothe expandable tubular member 2330. The expansion cone 2335 ispreferably adapted to radially expand the expandable tubular member 2330when the expansion cone 2335 is axially displaced relative to theexpandable tubular member 2330.

In an exemplary embodiment, the expansion cone 2335 is providedsubstantially as disclosed in one or more of the following: (1) U.S.utility patent application Ser. No. 09/454,139, attorney docket no.25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of thefiling date of U.S. provisional patent application No. 60/111,293,attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utilitypatent application Ser. No. 09/510,913, attorney docket no. 25791.7.02,filed on Feb. 23, 2000, which claimed the benefit of the filing date ofU.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3)U.S. utility patent application Ser. No. 09/502,350, attorney docket no.25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of thefiling date of U.S. provisional application No. 60/119,611, attorneydocket no. 25791.8; (4) U.S. utility patent application Ser. No.09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/108,558, attorney docket no. 25791.9, filed on Nov.16, 1998; (5) U.S. provisional patent application No. 60/183,546, filedon Feb. 18, 2000; (6) U.S. utility patent application Ser. No.09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utilitypatent application Ser. No. 09/512,895, attorney docket no. 25791.12.02,filed on Feb. 24, 2000, which claimed the benefit of the filing dates ofU.S. provisional application No. 60/121,841, attorney docket no.25791.12, filed on Feb. 26, 1999 and U.S. provisional application Ser.No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999;(8) U.S. utility application Ser. No. 09/511,941, attorney docket no.25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of thefiling date of U.S. provisional Ser. No. 60/121,907, attorney docket no.25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent applicationSer. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7,2000, which claimed the benefit of the filing date of U.S. provisionalpatent application Ser. No. 60/137,998, attorney docket no. 25791.17,filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No.09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/131,106, attorney docket no. 25791.23, filed on Apr.26, 1999; (11) U.S. provisional application Ser. No. 60/146,203,attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S.provisional application No. 60/143,039, attorney docket no. 25791.26,filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No.60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14)U.S. provisional application Ser. No. 60/159,039, attorney docket no.25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patentapplication No. 60/159,033, attorney docket no. 25791.37, filed on Oct.12, 1999; and (16) U.S. provisional patent application No. 60/165,228,attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures ofwhich are incorporated herein by reference.

The upper sealing member 2340 is coupled to the outside surface of theupper section 2360 of the expandable tubular member 2330. The uppersealing member 2340 is preferably adapted to fluidicly seal theinterface between the radially expanded upper section 2360 of theexpandable tubular member 2330 and the wellbore casing 2300. The uppersealing member 2340 may be any number of conventional commerciallyavailable sealing members. In an exemplary embodiment, the upper sealingmember 2340 is a viton rubber in order to optimally provide loadcarrying and pressure sealing capacity.

The lower sealing member 2345 is preferably coupled to the outsidesurface of the upper section 2360 of the expandable tubular member 2330.The lower sealing member 2340 is preferably adapted to fluidicly sealthe interface between the radially expanded upper section 2360 of theexpandable tubular member 2330 and the open hole wellbore section 2305.The lower sealing member 2345 may be any number of conventionalcommercially available sealing members. In an exemplary embodiment, thelower sealing member 2345 is viton rubber in order to optimally provideload carrying and sealing capacity.

As illustrated in FIG. 23 a, the apparatus 2320 is preferably positionedwithin the wellbore casing 2300 and the open hole wellbore section 2305with the expandable tubular member 2330 positioned in overlappingrelation to the wellbore casing 2300.

As illustrated in FIG. 23 b, in an exemplary embodiment, a quantity of ahardenable fluidic sealing material 2365 is then injected into the openhole wellbore section 2305 proximate to the lower section 2350 of theexpandable tubular member 2330. The sealing material 2365 may be anynumber of conventional commercially available sealing materials such as,for example, cement and/or epoxy resin. In an exemplary embodiment, thehardenable fluidic sealing material 2365 at least partially enters theslots provided in the lower section 2350 of the expandable tubularmember 2330.

As illustrated in FIG. 23 c, the hardenable fluidic sealing material2365 is preferably then permitted to at least partially cure. In thismanner, the lower section 2350 of the expandable tubular member 2330 isanchored to the open hole wellbore section 2305.

In an alternative embodiment, a compressible cement and/or epoxy is theninjected into the annular space between the unexpanded portion of thetubular member 2330 and the wellbore casing 2300. The compressiblecement and/or epoxy is then permitted to at least partially cure priorto the initiation of the radial expansion process. In this manner, anannular structural support and fluidic seal is provided around thetubular member 2330.

As illustrated in FIG. 23 d, in an exemplary embodiment, the expansioncone 2335 is then axially displaced by applying an axial force to thesupport member 2325. In an exemplary embodiment, the axial displacementof the expansion cone 2335 radially expands the expandable tubularmember 2330 into intimate contact with the walls of the wellbore casing2300.

As illustrated in FIG. 23 e, in an exemplary embodiment, after theexpandable tubular member 2330 has been completely radially expanded bythe axial displacement of the expansion cone 2335, a new section ofwellbore casing is formed that preferably includes the radially expandedtubular member 2330 and an outer annular layer of a fluidic sealingmaterial. More generally, the apparatus 2320 is used to repair or formwellbore casings, pipelines, and structural supports.

Referring to FIGS. 24 a to 24 c, an alternative embodiment of anapparatus and method for coupling an expandable tubular member to apreexisting structure will now be described. Referring to FIG. 24 a, awellbore casing 2400 and an open hole wellbore section 2405 arepositioned within a subterranean formation 2410. The wellbore casing2400 and the open hole wellbore section 2405 may be positioned in anyorientation from the vertical direction to approximately the horizontaldirection.

In an exemplary embodiment, an apparatus 2420 is utilized to form a newsection of wellbore casing within the open hole wellbore section 2405.More generally, the apparatus 2420 is preferably utilized to form orrepair wellbore casings, pipelines, or structural supports.

The apparatus 2420 preferably includes a support member 2425, anexpandable tubular member 2430, an expansion cone 2435, a coupling 2440,a packer 2445, a mass 2450, one or more upper sealing members 2455, andone or more sealing members 2460.

The support member 2425 is preferably adapted to be coupled to a surfacelocation. The support member 2425 is further coupled to the expansioncone 2435. The support member 2425 is preferably adapted to conveyelectrical, communication, and/or hydraulic signals to and/or from thepacker 2445. The support member 2425 may, for example, be conventionalcommercially available slick wire, braided wire, coiled tubing, ordrilling stock material.

The expandable tubular member 2430 is removably coupled to the expansioncone 2435 and the packer 2445. The expandable tubular member 2430 isfurther preferably coupled to the mass 2450. In an exemplary embodiment,the expandable tubular member 2430 further includes one or more upperand lower sealing members, 2455 and 2460, on the outside surface of theexpandable tubular member 2430 in order to optimally seal the interfacebetween the expandable tubular member 2430 and the wellbore casing 2400and the open hole wellbore section 2405.

In an exemplary embodiment, the expandable tubular member 2430 furtherincludes a lower section 2465, an intermediate section 2470, and anupper section 2430. In an exemplary embodiment, the wall thicknesses ofthe lower and intermediate sections, 2465 and 2470, are less than thewall thickness of the upper section 2475 in order to optimallyfacilitate the radial expansion of the expandable tubular member 2430.In an exemplary embodiment, the lower section 2465 of the expandabletubular member 2430 is coupled to the mass 2450.

In an exemplary embodiment, the expandable tubular member 2430 isfurther provided substantially as disclosed in one or more of thefollowing:

The expansion cone 2435 is preferably coupled to the support member 2425and the coupling 2440. The expansion cone 2435 is further preferablyremovably coupled to the expandable tubular member 2430. The expansioncone 2435 is preferably adapted to radially expand the expandabletubular member 2430 when the expansion cone 2435 is axially displacedrelative to the expandable tubular member 2430.

In an exemplary embodiment, the expansion cone 2435 is providedsubstantially as disclosed in one or more of the following: (1) U.S.utility patent application Ser. No. 09/454,139, attorney docket no.25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of thefiling date of U.S. provisional patent application No. 60/111,293,attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utilitypatent application Ser. No. 09/510,913, attorney docket no. 25791.7.02,filed on Feb. 23, 2000, which claimed the benefit of the filing date ofU.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3)U.S. utility patent application Ser. No. 09/502,350, attorney docket no.25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of thefiling date of U.S. provisional application No. 60/119,611, attorneydocket no. 25791.8; (4) U.S. utility patent application Ser. No.09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/108,558, attorney docket no. 25791.9, filed on Nov.16, 1998; (5) U.S. provisional patent application No. 60/183,546, filedon Feb. 18, 2000; (6) U.S. utility patent application Ser. No.09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utilitypatent application Ser. No. 09/512,895, attorney docket no. 25791.12.02,filed on Feb. 24, 2000, which claimed the benefit of the filing dates ofU.S. provisional application No. 60/121,841, attorney docket no.25791.12, filed on Feb. 26, 1999 and U.S. provisional application Ser.No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999;(8) U.S. utility application Ser. No. 09/511,941, attorney docket no.25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of thefiling date of U.S. provisional Ser. No. 60/121,907, attorney docket no.25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent applicationSer. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7,2000, which claimed the benefit of the filing date of U.S. provisionalpatent application Ser. No. 60/137,998, attorney docket no. 25791.17,filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No.09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/131,106, attorney docket no. 25791.23, filed on Apr.26, 1999; (11) U.S. provisional application Ser. No. 60/146,203,attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S.provisional application No. 60/143,039, attorney docket no. 25791.26,filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No.60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14)U.S. provisional application Ser. No. 60/159,039, attorney docket no.25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patentapplication No. 60/159,033, attorney docket no. 25791.37, filed on Oct.12, 1999; and (16) U.S. provisional patent application No. 60/165,228,attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures ofwhich are incorporated herein by reference.

The coupling 2440 is preferably coupled to the support member 2425 andthe expansion cone 2435. The coupling 2440 is preferably adapted toconvey electrical, communication, and/or hydraulic signals to and/orfrom the packer 2445. The coupling 2440 may be any number ofconventional support members such as, for example, commerciallyavailable slick wire, braided wire, coiled tubing, or drilling stockmaterial.

The packer 2445 is coupled to the coupling 2440. The packer 2445 isfurther removably coupled to the lower section 2465 of the expandablewellbore casing 2430. The packer 2445 is preferably adapted to providesufficient frictional force to support the lower section 2465 of theexpandable wellbore casing 2430 and the mass 2450. The packer 2445 maybe any number of conventional commercially available packers. In anexemplary embodiment, the packer 2445 is an RTTS packer available fromHalliburton Energy Services in order to optimally provide multiple setsand releases. In an alternative embodiment, hydraulic slips may besubstituted for, or used to supplement, the packer 2445.

The mass 2450 is preferably coupled to the lower section 2465 of theexpandable tubular member 2430. The mass 2450 is preferably selected toprovide a tensile load on the lower section 2465 of the expandabletubular member 2430 that ranges from about 50 to 100% of the yield pointof the upper section 2475 of the expandable tubular member 2430. In thismanner, when the packer 2445 is released, the axial force provided bythe mass 2450 optimally radially expands and extrudes the expandabletubular member 2430 off of the expansion cone 2435.

The upper sealing member 2455 is preferably coupled to the outsidesurface of the upper section 2475 of the expandable tubular member 2430.The upper sealing member 2455 is preferably adapted to fluidicly sealthe interface between the radially expanded upper section 2475 of theexpandable tubular member 2430 and the wellbore casing 2400. The uppersealing member 2455 may be any number of conventional commerciallyavailable sealing members. In an exemplary embodiment, the upper sealingmember 2455 is viton rubber in order to optimally provide load carryingand pressure sealing capacity.

The lower sealing member 2460 is preferably coupled to the outsidesurface of the upper section 2475 of the expandable tubular member 2430.The lower sealing member 2460 is preferably adapted to fluidicly sealthe interface between the radially expanded upper section 2475 of theexpandable tubular member 2430 and the open hole wellbore section 2405.The lower sealing member 2460 may be any number of conventionalcommercially available sealing members. In an exemplary embodiment, thelower sealing member 2460 is viton rubber in order to optimally providelead bearing and sealing capacity.

As illustrated in FIG. 24 a, the apparatus 2420 is preferably positionedwithin the wellbore casing 2400 and the open hole wellbore section 2405with the expandable tubular member 2430 positioned in overlappingrelation to the wellbore casing 2400. In an exemplary embodiment, theweight of the mass 2450 is supported by the support member 2425, theexpansion cone 2435, the coupling 2440, the packer 2445, and the lowersection 2465 of the expandable tubular member 2430. In this manner, theintermediate section 2470 of the expandable tubular member 2430preferably does not support any of the weight of the mass 2450.

As illustrated in FIG. 24 b, in an exemplary embodiment, the packer 2445is then released from connection with the lower section 2465 of theexpandable tubular member 2430. In this manner, the mass 2450 ispreferably now supported by the support member 2425, expansion cone2435, and the lower and intermediate sections, 2465 and 2470, of theexpandable tubular member 2430. In an exemplary embodiment, the weightof the mass 2450 then causes the expandable tubular member 2430 to beradially expanded by, and extruded off of, the expansion cone 2435. Inan exemplary embodiment, during the extrusion process, the position ofthe support member 2425 is adjusted to ensure an overlapping relationbetween the expandable tubular member 2430 and the wellbore casing 2400.

In an alternative embodiment, a compressible cement and/or epoxy isinjected into the annular space between the unexpanded portion of thetubular member 2430 and the wellbore casing 2400 before and/or duringthe extrusion process. The compressible cement and/or epoxy is thenpreferably permitted to at least partially cure prior to the initiationof the radial expansion process. In this manner, an annular structuralsupport and fluidic seal is provided around the tubular member 2430.

As illustrated in FIG. 24 c, in an exemplary embodiment, after theexpandable tubular member 2430 has been completely extruded off of theexpansion cone 2435, a new section of wellbore casing is formed thatpreferably includes the radially expanded tubular member 2430 and anouter annular layer of a fluidic sealing material. More generally, theapparatus 2420 is used to repair or form wellbore casings, pipelines,and structural supports.

In an alternative embodiment, the mass 2450 is positioned on top of theupper section 2475 of the tubular member 2430. In an exemplaryembodiment, the mass 2450 is fabricated from a thick walled tubularmember that is concentric with respect to the support member 2425, andalso rests on top of the upper section 2475 of the tubular member 2430.In this manner, when the expansion cone 2435 exits the tubular member2430, the expansion cone will carry the mass 2450 out of the wellbore2405.

Referring to FIGS. 25 a to 25 c, an alternative embodiment of anapparatus and method for coupling an expandable tubular member to apreexisting structure will now be described. Referring to FIG. 25 a, awellbore casing 2500 and an open hole wellbore section 2505 arepositioned within a subterranean formation 2510. The wellbore casing2500 and the open hole wellbore section 2505 may be positioned in anyorientation from the vertical direction to approximately the horizontaldirection.

In an exemplary embodiment, an apparatus 2520 is utilized to form a newsection of wellbore casing within the open hole wellbore section 2505.More generally, the apparatus 2520 is preferably utilized to form orrepair wellbore casings, pipelines, or structural supports.

The apparatus 2520 preferably includes a support member 2525, anexpandable tubular member 2530, an expansion cone 2535, a chamber 2440,an end plate 2545, one or more upper sealing members 2555, and one ormore sealing members 2560.

The support member 2525 is preferably adapted to be coupled to a surfacelocation. The support member 2525 is further coupled to the expansioncone 2535. The support member 2525 is preferably adapted to conveyfluidic materials to and/or from the chamber 2540. The support member2525 may, for example, be conventional commercially available slickwire, braided wire, coiled tubing, or drilling stock material.

The expandable tubular member 2530 is removably coupled to the expansioncone 2535. In an exemplary embodiment, the expandable tubular member2530 further includes one or more upper and lower sealing members, 2555and 2560, on the outside surface of the expandable tubular member 2530in order to optimally seal the interface between the expandable tubularmember 2530 and the wellbore casing 2500 and the open hole wellboresection 2505.

In an exemplary embodiment, the expandable tubular member 2530 furtherincludes a lower section 2565, an intermediate section 2570, and anupper section 2530. In an exemplary embodiment, the wall thicknesses ofthe lower and intermediate sections, 2565 and 2570, are less than thewall thickness of the upper section 2575 in order to optimallyfacilitate the radial expansion of the expandable tubular member 2530.

In an exemplary embodiment, the lower section 2565 of the expandabletubular member 2530 further includes the chamber 2540 and the end plate2545.

In an exemplary embodiment, the expandable tubular member 2530 isfurther provided substantially as disclosed in one or more of thefollowing: (1) U.S. utility patent application Ser. No. 09/454,139,attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed thebenefit of the filing date of U.S. provisional patent application No.60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S.utility patent application Ser. No. 09/510,913, attorney docket no.25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of thefiling date of U.S. provisional application No. 60/121,702, filed onFeb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350,attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimedthe benefit of the filing date of U.S. provisional application No.60/119,611, attorney docket no. 25791.8; (4) U.S. utility patentapplication Ser. No. 09/440,338, attorney docket no. 25791.9.02, filedon Nov. 15, 1999, which claimed the benefit of the filing date of U.S.provisional application No. 60/108,558, attorney docket no. 25791.9,filed on Nov. 16, 1998; (5) U.S. provisional patent application No.60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent applicationSer. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10,2000, which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utilitypatent application Ser. No. 09/512,895, attorney docket no. 25791.12.02,filed on Feb. 24, 2000, which claimed the benefit of the filing dates ofU.S. provisional application No. 60/121,841, attorney docket no.25791.12, filed on Feb. 26, 1999 and U.S. provisional application Ser.No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999;(8) U.S. utility application Ser. No. 09/511,941, attorney docket no.25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of thefiling date of U.S. provisional Ser. No. 60/121,907, attorney docket no.25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent applicationSer. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7,2000, which claimed the benefit of the filing date of U.S. provisionalpatent application Ser. No. 60/137,998, attorney docket no. 25791.17,filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No.09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/131,106, attorney docket no. 25791.23, filed on Apr.26, 1999; (11) U.S. provisional application Ser. No. 60/146,203,attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S.provisional application No. 60/143,039, attorney docket no. 25791.26,filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No.60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14)U.S. provisional application Ser. No. 60/159,039, attorney docket no.25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patentapplication No. 60/159,033, attorney docket no. 25791.37, filed on Oct.12, 1999; and (16) U.S. provisional patent application No. 60/165,228,attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures ofwhich are incorporated herein by reference.

The expansion cone 2535 is preferably coupled to the support member2525. The expansion cone 2535 is further preferably removably coupled tothe expandable tubular member 2530. The expansion cone 2535 ispreferably adapted to radially expand the expandable tubular member 2530when the expansion cone 2535 is axially displaced relative to theexpandable tubular member 2530. The expansion cone 2535 is furtherpreferably adapted to convey fluidic materials to and/or from thechamber 2540.

In an exemplary embodiment, the expansion cone 2535 is providedsubstantially as disclosed in one or more of the following: (1) U.S.utility patent application Ser. No. 09/454,139, attorney docket no.25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of thefiling date of U.S. provisional patent application No. 60/111,293,attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utilitypatent application Ser. No. 09/510,913, attorney docket no. 25791.7.02,filed on Feb. 23, 2000, which claimed the benefit of the filing date ofU.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3)U.S. utility patent application Ser. No. 09/502,350, attorney docket no.25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of thefiling date of U.S. provisional application No. 60/119,611, attorneydocket no. 25791.8; (4) U.S. utility patent application Ser. No.09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/108,558, attorney docket no. 25791.9, filed on Nov.16, 1998; (5) U.S. provisional patent application No. 60/183,546, filedon Feb. 18, 2000; (6) U.S. utility patent application Ser. No.09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utilitypatent application Ser. No. 09/512,895, attorney docket no. 25791.12.02,filed on Feb. 24, 2000, which claimed the benefit of the filing dates ofU.S. provisional application No. 60/121,841, attorney docket no.25791.12, filed on Feb. 26, 1999 and U.S. provisional application Ser.No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999;(8) U.S. utility application Ser. No. 09/511,941, attorney docket no.25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of thefiling date of U.S. provisional Ser. No. 60/121,907, attorney docket no.25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent applicationSer. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7,2000, which claimed the benefit of the filing date of U.S. provisionalpatent application Ser. No. 60/137,998, attorney docket no. 25791.17,filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No.09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/131,106, attorney docket no. 25791.23, filed on Apr.26, 1999; (11) U.S. provisional application Ser. No. 60/146,203,attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S.provisional application No. 60/143,039, attorney docket no. 25791.26,filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No.60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14)U.S. provisional application Ser. No. 60/159,039, attorney docket no.25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patentapplication No. 60/159,033, attorney docket no. 25791.37, filed on Oct.12, 1999; and (16) U.S. provisional patent application No. 60/165,228,attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures ofwhich are incorporated herein by reference.

The chamber 2540 is defined by the interior portion of the lower section2565 of the expandable tubular member 2530 below the expansion cone 2535and above the end plate 2545. The chamber 2540 is preferably adapted tocontain a quantity of a fluidic materials having a higher density thanthe fluidic materials outside of the expandable tubular member 2530.

The upper sealing member 2555 is preferably coupled to the outsidesurface of the upper section 2575 of the expandable tubular member 2530.The upper sealing member 2555 is preferably adapted to fluidicly sealthe interface between the radially expanded upper section 2575 of theexpandable tubular member 2530 and the wellbore casing 2500. The uppersealing member 2555 may be any number of conventional commerciallyavailable sealing members. In an exemplary embodiment, the upper sealingmember 2555 is viton rubber in order to optimally provide load carryingand pressure sealing capacity.

The lower sealing member 2560 is preferably coupled to the outsidesurface of the upper section 2575 of the expandable tubular member 2530.The lower sealing member 2560 is preferably adapted to fluidicly sealthe interface between the radially expanded upper section 2575 of theexpandable tubular member 2530 and the open hole wellbore section 2505.The lower sealing member 2560 may be any number of conventionalcommercially available sealing members. In an exemplary embodiment, thelower sealing member 2560 is viton rubber in order to optimally provideload carrying and pressure sealing capacity.

As illustrated in FIG. 25 a, the apparatus 2520 is preferably positionedwithin the wellbore casing 2500 and the open hole wellbore section 2505with the expandable tubular member 2530 positioned in overlappingrelation to the wellbore casing 2500.

As illustrated in FIG. 25 b, a quantity of a fluidic material 2580having a density greater than the density of the fluidic material withinthe region 2585 outside of the expandable tubular member 2530 isinjected into the chamber 2540. In an exemplary embodiment, thedifference in hydrostatic pressure between the chamber 2540 and theregion 2585, due to the differences in fluid densities of these regions,causes the expandable tubular member 2530 to be radially expanded by,and extruded off of, the expansion cone 2535. In an exemplaryembodiment, during the extrusion process, the position of the supportmember 2525 is adjusted to ensure an overlapping relation between theexpandable tubular member 2530 and the wellbore casing 2500. In anexemplary embodiment, the quantity of the fluidic material 2580initially injected into the chamber 2540 is subsequently increased asthe size of the chamber 2540 increases during the extrusion process. Inthis manner, high pressure pumping equipment is typically not required,or the need for it is at least minimized. Rather, in an exemplaryembodiment, a column of the fluidic material 2580 is maintained withinthe support member 2525.

In an alternative embodiment, a compressible cement and/or epoxy isinjected into the annular space between the unexpanded portion of thetubular member 2530 and the wellbore casing 2500 before and/or duringthe extrusion process. The compressible cement and/or epoxy is thenpreferably permitted to at least partially cure prior to the initiationof the radial expansion process. In this manner, an annular structuralsupport and fluidic seal is provided around the tubular member 2530.

As illustrated in FIG. 25 c, in an exemplary embodiment, after theexpandable tubular member 2530 has been completely extruded off of theexpansion cone 2535, a new section of wellbore casing is formed thatpreferably includes the radially expanded tubular member 2530 and anouter annular layer of a fluidic sealing material. More generally, theapparatus 2520 is used to repair or form wellbore casings, pipelines,and structural supports.

Referring to FIGS. 26 a to 26 c, an alternative embodiment of anapparatus and method for coupling an expandable tubular member to apreexisting structure will now be described. Referring to FIG. 26 a, awellbore casing 2600 and an open hole wellbore section 2605 arepositioned within a subterranean formation 2610. The wellbore casing2600 and the open hole wellbore section 2605 may be positioned in anyorientation from the vertical direction to approximately the horizontaldirection.

In an exemplary embodiment, an apparatus 2620 is utilized to form a newsection of wellbore casing within the open hole wellbore section 2605.More generally, the apparatus 2620 is preferably utilized to form orrepair wellbore casings, pipelines, or structural supports.

The apparatus 2620 preferably includes a support member 2625, anexpandable tubular member 2630, an expansion cone 2635, a slip joint2640, an end plate 2545, a chamber 2650, one or more slip members 2655,one or more sealing members 2670, one or more upper sealing members2675, and one or more lower sealing members 2680.

The support member 2625 is preferably adapted to be coupled to a surfacelocation. The support member 2625 is further coupled to the expansioncone 2635. The support member 2625 is preferably adapted to conveyfluidic materials to and/or from the chamber 2640. The support member2625 may, for example, be conventional commercially available slickwire, braided wire, coiled tubing, or drilling stock material.

The expandable tubular member 2630 is removably coupled to the expansioncone 2635. In an exemplary embodiment, the expandable tubular member2630 further includes one or more upper and lower sealing members, 2675and 2680, on the outside surface of the expandable tubular member 2630in order to optimally seal the interface between the expandable tubularmember 2630 and the wellbore casing 2600 and the open hole wellboresection 2605.

In an exemplary embodiment, the expandable tubular member 2630 furtherincludes a lower section 2685, an intermediate section 2690, and anupper section 2695. In an exemplary embodiment, the wall thicknesses ofthe lower and intermediate sections, 2685 and 2690, are less than thewall thickness of the upper section 2695 in order to optimallyfacilitate the radial expansion of the expandable tubular member 2630.

In an exemplary embodiment, the lower section 2685 of the expandabletubular member 2630 houses the slip joint 2640, the end plate 2645, theslips 2655, and the sealing members 2670. In an exemplary embodiment,the interior portion of the lower section 2685 of the expandable tubularmember 2630 below the expansion cone 2635 and above the end platedefines the chamber 2650. In an exemplary embodiment, the lower section2685 of the expandable tubular member 2630 further includes one or moreof the anchoring devices described above with reference to FIGS. 1 a to25 c.

In an exemplary embodiment, the expandable tubular member 2630 isfurther provided substantially as disclosed in one or more of thefollowing: (1) U.S. utility patent application Ser. No. 09/454,139,attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed thebenefit of the filing date of U.S. provisional patent application No.60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S.utility patent application Ser. No. 09/510,913, attorney docket no.25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of thefiling date of U.S. provisional application No. 60/121,702, filed onFeb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350,attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimedthe benefit of the filing date of U.S. provisional application No.60/119,611, attorney docket no. 25791.8; (4) U.S. utility patentapplication Ser. No. 09/440,338, attorney docket no. 25791.9.02, filedon Nov. 15, 1999, which claimed the benefit of the filing date of U.S.provisional application No. 60/108,558, attorney docket no. 25791.9,filed on Nov. 16, 1998; (5) U.S. provisional patent application No.60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent applicationSer. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10,2000, which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utilitypatent application Ser. No. 09/512,895, attorney docket no. 25791.12.02,filed on Feb. 24, 2000, which claimed the benefit of the filing dates ofU.S. provisional application No. 60/121,841, attorney docket no.25791.12, filed on Feb. 26, 1999 and U.S. provisional application Ser.No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999;(8) U.S. utility application Ser. No. 09/511,941, attorney docket no.25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of thefiling date of U.S. provisional Ser. No. 60/121,907, attorney docket no.25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent applicationSer. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7,2000, which claimed the benefit of the filing date of U.S. provisionalpatent application Ser. No. 60/137,998, attorney docket no. 25791.17,filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No.09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication no. 60/131,106, attorney docket no. 25791.23, filed on Apr.26, 1999; (11) U.S. provisional application Ser. No. 60/146,203,attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S.provisional application No. 60/143,039, attorney docket no. 25791.26,filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No.60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14)U.S. provisional application Ser. No. 60/159,039, attorney docket no.25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patentapplication No. 60/159,033, attorney docket no. 25791.37, filed on Oct.12, 1999; and (16) U.S. provisional patent application No. 60/165,228,attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures ofwhich are incorporated herein by reference.

The expansion cone 2635 is preferably coupled to the support member 2625and the slip joint 2640. The expansion cone 2635 is further preferablyremovably coupled to the expandable tubular member 2630. The expansioncone 2635 is preferably adapted to radially expand the expandabletubular member 2630 when the expansion cone 2635 is axially displacedrelative to the expandable tubular member 2630. The expansion cone 2635is further preferably adapted to convey fluidic materials to and/or fromthe chamber 2650.

In an exemplary embodiment, the expansion cone 2635 is further providedsubstantially as disclosed in one or more of the following: (1) U.S.utility patent application Ser. No. 09/454,139, attorney docket no.25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of thefiling date of U.S. provisional patent application No. 60/111,293,attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utilitypatent application Ser. No. 09/510,913, attorney docket no. 25791.7.02,filed on Feb. 23, 2000, which claimed the benefit of the filing date ofU.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3)U.S. utility patent application Ser. No. 09/502,350, attorney docket no.25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of thefiling date of U.S. provisional application No. 60/119,611, attorneydocket no. 25791.8; (4) U.S. utility patent application Ser. No.09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/108,558, attorney docket no. 25791.9, filed on Nov.16, 1998; (5) U.S. provisional patent application No. 60/183,546, filedon Feb. 18, 2000; (6) U.S. utility patent application Ser. No.09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utilitypatent application Ser. No. 09/512,895, attorney docket no. 25791.12.02,filed on Feb. 24, 2000, which claimed the benefit of the filing dates ofU.S. provisional application No. 60/121,841, attorney docket no.25791.12, filed on Feb. 26, 1999 and U.S. provisional application Ser.No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999;(8) U.S. utility application Ser. No. 09/511,941, attorney docket no.25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of thefiling date of U.S. provisional Ser. No. 60/121,907, attorney docket no.25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent applicationSer. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7,2000, which claimed the benefit of the filing date of U.S. provisionalpatent application Ser. No. 60/137,998, attorney docket no. 25791.17,filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No.09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000,which claimed the benefit of the filing date of U.S. provisionalapplication no. 60/131,106, attorney docket no. 25791.23, filed on Apr.26, 1999; (11) U.S. provisional application Ser. No. 60/146,203,attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S.provisional application No. 60/143,039, attorney docket no. 25791.26,filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No.60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14)U.S. provisional application Ser. No. 60/159,039, attorney docket no.25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patentapplication No. 60/159,033, attorney docket no. 25791.37, filed on Oct.12, 1999; and (16) U.S. provisional patent application No. 60/165,228,attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures ofwhich are incorporated herein by reference.

The slip joint 2640 is coupled to the expansion cone 2635 and the endplate 2645. The slip joint 2640 is preferably adapted to permit the endplate 2645 to be axially displaced relative to the expansion cone 2635.In this manner, the size of the chamber 2650 is variable. The slip joint2640 may be any number of conventional commercially available slipjoints modified in accordance with the teachings of the presentdisclosure.

The slip joint 2640 preferably includes an upper member 2640 a, aresilient member 2640 b, and a lower member 2640 c. The upper member2640 a is coupled to the expansion cone 2635 and the resilient member2640 b. The upper member 2640 a is movably coupled to the lower member2640 b. The upper member 2640 a preferably includes one or more fluidpassages 2640 aa that permit the passage of fluidic materials. The lowermember 2640 b is coupled to the end plate 2645 and the resilient member2640 b. The lower member 2640 b is movably coupled to the upper member2640 a. The lower member 2640 b preferably includes one or more fluidpassages 2640 ba that permit the passage of fluidic materials. Theresilient member 2640 c is coupled between the upper and lower members,2640 a and 2640 b. The resilient member 2640 c is preferably adapted toapply an upward axial force to the end plate 2645.

The end plate 2645 is coupled to the slip joint 2640, the slips 2655,and the sealing members 2670. The end plate 2645 is preferably adaptedto seal off a portion of the interior of the lower section 2685 of theexpandable tubular member 2630. The end plate 2645 is further adapted todefine, in combination with the expandable tubular member 2630, and theexpansion cone 2635, the chamber 2650.

The chamber 2650 is defined by the interior portion of the lower section2685 of the expandable tubular member 2630 below the expansion cone 2635and above the end plate 2645. In an exemplary embodiment, thepressurization of the chamber 2650 causes the expansion cone 2635 to beaxially displaced and thereby radially expand the expandable tubularmember 2630. The chamber 2650 is preferably adapted to move upwardlywithin the expandable tubular member 2630 as the expansion cone 2635 andend plate 2645 are axially displaced within the expandable tubularmember 2630.

The slips 2655 are coupled to the end plate 2645. The slips 2655 arepreferably adapted to permit the end plate 2645 to be displaced in theupward axial direction; but prevent axial displacement of the end plate2645 in the downward direction. In this manner, the chamber 2650 ispressurized by injecting fluidic materials into the chamber 2650.Because the end plate 2645 is maintained in a substantially stationaryposition, relative to the expandable tubular member 2630, during theinjection of pressurized fluidic materials into the chamber 2650, thepressurization of the chamber 2650 preferably axially displaces theexpansion cone 2635. In an exemplary embodiment, when the slip joint2640 is fully extended, the slip joint 2640 then displaces the end plate2645 in the upward axial direction. In an exemplary embodiment, when thespring force of the elastic member 2640 c of the slip joint 2640 isgreater than the fluidic pressurization force within the chamber 2650,the end plate 2645 is displaced in the upward axial direction.

The sealing members 2670 are coupled to the end plate 2645. The sealingmembers 2670 are further preferably sealingly coupled to the interiorwalls of the expandable tubular member 2630. In this manner, the chamber2650 is optimally pressurized during operation of the apparatus 2620.

The upper sealing member 2675 is preferably coupled to the outsidesurface of the upper section 2695 of the expandable tubular member 2630.The upper sealing member 2675 is preferably adapted to fluidicly sealthe interface between the radially expanded upper section 2695 of theexpandable tubular member 2630 and the wellbore casing 2600. The uppersealing member 2675 may be any number of conventional commerciallyavailable sealing members. In an exemplary embodiment, the upper sealingmember 2675 is viton rubber in order to optimally provide load carryingand pressure sealing capacity.

The lower sealing member 2680 is preferably coupled to the outsidesurface of the upper section 2695 of the expandable tubular member 2630.The lower sealing member 2680 is preferably adapted to fluidicly sealthe interface between the radially expanded upper section 2695 of theexpandable tubular member 2630 and the open hole wellbore section 2605.The lower sealing member 2680 may be any number of conventionalcommercially available sealing members. In an exemplary embodiment, thelower sealing member 2680 is viton rubber in order to optimally provideload carrying and pressure sealing capacity.

As illustrated in FIG. 26 a, the apparatus 2620 is preferably positionedwithin the wellbore casing 2600 and the open hole wellbore section 2605with the expandable tubular member 2630 positioned in overlappingrelation to the wellbore casing 2600. In an exemplary embodiment, thelower section 2685 of the expandable tubular member 2630 is thenanchored to the open hole wellbore section 2605 using one or more of theapparatus and methods described above with reference to FIGS. 1 a to 25c.

As illustrated in FIG. 26 b, the radial expansion of the expandabletubular member 2630 is then initiated by: (1) applying an upward axialforce to the expansion cone 2635; and/or (2) pressurizing the chamber2650 by injecting a pressurized fluidic material into the chamber 2650.

In an exemplary embodiment, the expandable tubular member 2630 isradially expanded by applying an upward axial force to the expansioncone 2635. In an exemplary embodiment, once the slip joint 2640 is fullyextended, the end plate 2645 is then axially displaced in the upwarddirection. In this manner, the end plate 2645 follows the expansion cone2635. In an exemplary embodiment, the chamber 2650 is pressurized whenthe frictional forces exceed a predetermined value. In this manner, theaxial displacement of the expansion cone 2635 is provided by applying anaxial force that is selectively supplemented by pressurizing the chamber2650.

In an alternative embodiment, a compressible cement and/or epoxy isinjected into the annular space between the unexpanded portion of thetubular member 2630 and the wellbore casing 2600 before and/or duringthe extrusion process. The compressible cement and/or epoxy is thenpreferably permitted to at least partially cure prior to the initiationof the radial expansion process. In this manner, an annular structuralsupport and fluidic seal is provided around the tubular member 2630.

As illustrated in FIG. 26 c, in an exemplary embodiment, after theexpandable tubular member 2630 has been completely extruded off of theexpansion cone 2635, a new section of wellbore casing is formed thatpreferably includes the radially expanded tubular member 2630 and anouter annular layer of a fluidic sealing material. More generally, theapparatus 2620 is used to repair or form wellbore casings, pipelines,and structural supports.

Referring initially to FIG. 27, an exemplary method 2700 of coupling anexpandable tubular member to a preexisting structure includes the stepsof: (1) coupling the expandable tubular member to the preexistingstructure by axially displacing an expansion cone; and (2) radiallyexpanding the expandable tubular by applying direct radial pressure.

In an exemplary embodiment, as illustrated in FIG. 28, in step 2705, anexpandable tubular member 2805 is coupled to a preexisting wellborecasing 2810 positioned within a subterranean formation 2815. In anexemplary embodiment, the wellbore casing 2810 further includes an outerannular layer 2820 of a fluidic sealing material such as, for example,cement. The expandable tubular member 2805 may be coupled to thepreexisting wellbore casing 2810 using any number of conventionalcommercially available methods for coupling an expandable tubular memberto a preexisting structure such as, for example, pulling an expansioncone through a tubular member, or pushing an expansion cone through atubular member using a pressurized fluidic material. In an exemplaryembodiment, the expandable tubular member 2805 is coupled to thepreexisting structure 2810 using one or more of the apparatus andmethods disclosed in the following: (1) U.S. utility patent applicationSer. No. 09/454,139, attorney docket no. 25791.3.02, filed on Dec. 3,1999, which claimed the benefit of the filing date of U.S. provisionalpatent application No. 60/111,293, attorney docket no. 25791.3, filed onDec. 7, 1998; (2) U.S. utility patent application Ser. No. 09/510,913,attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimedthe benefit of the filing date of U.S. provisional application No.60/121,702, filed on Feb. 25, 1999; (3) U.S. utility patent applicationSer. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10,2000, which claimed the benefit of the filing date of U.S. provisionalapplication No. 60/119,611, attorney docket no. 25791.8; (4) U.S.utility patent application Ser. No. 09/440,338, attorney docket no.25791.9.02, filed on Nov. 15, 1999, which claimed the benefit of thefiling date of U.S. provisional application No. 60/108,558, attorneydocket no. 25791.9, filed on Nov. 16, 1998; (5) U.S. provisional patentapplication No. 60/183,546, filed on Feb. 18, 2000; (6) U.S. utilitypatent application Ser. No. 09/523,460, attorney docket no. 25791.11.02,filed on Mar. 10, 2000, which claimed the benefit of the filing date ofU.S. provisional application No. 60/124,042, filed on Mar. 11, 1999; (7)U.S. utility patent application Ser. No. 09/512,895, attorney docket no.25791.12.02, filed on Feb. 24, 2000, which claimed the benefit of thefiling dates of U.S. provisional application No. 60/121,841, attorneydocket no. 25791.12, filed on Feb. 26, 1999 and U.S. provisionalapplication Ser. No. 60/154,047, attorney docket no. 25791.29, filed onSep. 16, 1999; (8) U.S. utility application Ser. No. 09/511,941,attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claimedthe benefit of the filing date of U.S. provisional Ser. No. 60/121,907,attorney docket no. 25791.16, filed on Feb. 26, 1999; (9) U.S. utilitypatent application Ser. No. 09/588,946, attorney docket no. 25791.17.02,filed on Jun. 7, 2000, which claimed the benefit of the filing date ofU.S. provisional patent application Ser. No. 60/137,998, attorney docketno. 25791.17, filed on Jun. 7, 1999; (10) U.S. utility patentapplication Ser. No. 09/559,122, attorney docket no. 25791.23.02, filedon Apr. 26, 2000, which claimed the benefit of the filing date of U.S.provisional application No. 60/131,106, attorney docket no. 25791.23,filed on Apr. 26, 1999; (11) U.S. provisional application Ser. No.60/146,203, attorney docket no. 25791.25, filed on Jul. 29, 1999; (12)U.S. provisional application No. 60/143,039, attorney docket no.25791.26, filed on Jul. 9, 1999; (13) U.S. provisional patentapplication Ser. No. 60/162,671, attorney docket no. 25791.27, filed onNov. 1, 1999; (14) U.S. provisional application Ser. No. 60/159,039,attorney docket no. 25791.36, filed on Oct. 12, 1999; (15) U.S.provisional patent application No. 60/159,033, attorney docket no.25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patentapplication No. 60/165,228, attorney docket no. 25791.39, filed on Nov.12, 1999, the disclosures of which are incorporated herein by reference.In an exemplary embodiment, the amount of radial expansion provided instep 105 ranges from about 5% to 20%.

In an exemplary embodiment, as illustrated in FIG. 29, in step 2710, atleast a portion of the expandable tubular member 2805 is furtherradially expanded by using a radial expansion tool 2905 to apply directradial pressure to the expandable tubular member 2805. The radialexpansion tool 2905 may be any number of conventional radial expansiontools suitable for applying direct radial pressure to a tubular member.In an exemplary embodiment, the radial expansion tool 2905 is providedsubstantially as disclosed on one or more of the following U.S. Pat.Nos. 5,014,779 and 5,083,608, the disclosures of which are incorporatedherein by reference. In an exemplary embodiment, the amount of radialexpansion of the expandable tubular member 2805 provided in step 2710ranges up to about 5%. In an exemplary embodiment, the radial contactpressures generated by the radial expansion tool 2905 in step 2710 rangefrom about 5,000 to 140,000 psi. in order to optimally plasticallydeform the expandable tubular member 205 to the final desired geometry.

In an exemplary embodiment, the radial expansion provided in step 2705is limited to the portion of the expandable tubular member 2805 thatoverlaps with the preexisting wellbore casing 2810. In this manner, thehigh compressive forces typically required to radially expand theportion of the expandable tubular member 2805 that overlaps with thepreexisting wellbore casing 2810 are optimally provided.

In an alternative embodiment, the radial expansion in step 2705 radiallyexpands the expandable tubular member 2805 to provide an inside diametersubstantially equal to the inside diameter of the pre-existing wellborecasing 2810. In this manner, a mono-diameter wellbore casing isoptimally provided.

Thus, the method 2700 provides a 2-step radial expansion process thatutilizes: (1) a relatively quick method of radial expansion for themajority of the radial expansion; and (2) a high contact pressure methodfor the remaining radial expansion. In several alternative embodiments,the method 2700 is used to form or repair wellbore casings, pipelines,or structural supports.

The method 2700 further provides an apparatus and method for coupling anexpandable tubular member to a preexisting structure. The expandabletubular is initially coupled to the preexisting structure by axiallydisplacing an expansion cone within the expandable tubular member. Theexpandable tubular member is then further radially expanded by applyinga radial force to the expandable tubular. The apparatus and method havewide application to the formation and repair of wellbore casings,pipelines, and structural supports. The apparatus and method provide anefficient and reliable method for forming and repairing wellborecasings, pipelines, and structural supports. In an exemplaryimplementation, the initial radial expansion of the expandable tubularmember by axially displacing the expansion cone provide from about 5% to25% of radial expansion, and the subsequent application of direct radialpressure to the expandable tubular member provides an additional radialexpansion of up to about 10%. In this manner, the desired final geometryof the radially expanded tubular member is optimally achieved in a timeefficient and reliable manner. This method and apparatus is particularlyuseful in optimally creating profiles and seal geometries for liner topsand for connections between jointed tubulars.

In several alternative embodiments, the tubular members of the variousexemplary embodiments may be radially expanded and plastically deformedusing, for example, other types of conventional expansion tools such as,for example, conventional roller expansion devices such as, for example,the roller expansion devices commercially available from WeatherfordInternational.

A method of coupling an expandable tubular member to a preexistingstructure has been described that includes positioning the tubularmember and an expansion cone within the preexisting structure, anchoringthe tubular member to the preexisting structure, axially displacing theexpansion cone relative to the tubular member by pulling the expansioncone through the tubular member, and lubricating the interface betweenthe expansion cone and the tubular member. In an exemplary embodiment,lubricating the interface between the expansion cone and the tubularmember includes: injecting a lubricating fluid into the trailing edge ofthe interface between the expansion cone and the tubular member. In anexemplary embodiment, the lubricating fluid has a viscosity ranging fromabout 1 to 10,000 centipoise. In an exemplary embodiment, the injectingincludes: injecting lubricating fluid into a tapered end of theexpansion cone. In an exemplary embodiment, the injecting includes:injecting lubricating fluid into the area around the axial midpoint of afirst tapered end of the expansion cone. In an exemplary embodiment, theinjecting includes: injecting lubricating fluid into a second end of theexpansion cone. In an exemplary embodiment, the injecting includes:injecting lubricating fluid into a tapered first end and a second end ofthe expansion cone. In an exemplary embodiment, the injecting includes:injecting lubricating fluid into an interior of the expansion cone. Inan exemplary embodiment, the injecting includes: injecting lubricatingfluid through an outer surface of the expansion cone. In an exemplaryembodiment, the injecting includes: injecting the lubricating fluid intoa plurality of discrete locations along the trailing edge portion. In anexemplary embodiment, the lubricating fluid includes drilling mud. In anexemplary embodiment, the lubricating fluid further includes: TorqTrimIII, EP Mudlib, and DrillN-Slid. In an exemplary embodiment, thelubricating fluid includes TorqTrim III, EP Mudlib, and Drill-N-Slid. Inan exemplary embodiment, the interface between the expansion cone andthe tubular member includes: coating the interior surface of the tubularmember with a lubricant. In an exemplary embodiment, lubricating theinterface between the expansion cone and the tubular member includes:coating the interior surface of the tubular member with a first part ofa lubricant, and applying a second part of the lubricant to the interiorsurface of the tubular member. In an exemplary embodiment, the lubricantincludes a metallic soap. In an exemplary embodiment, the lubricant isselected from the group consisting of C-Lube-10, C-PHOS-58-M, andC-PHOS-58-R. In an exemplary embodiment, the lubricant provides asliding friction coefficient of less than about 0.20. In an exemplaryembodiment, the lubricant is chemically bonded to the interior surfacesof the tubular members. In an exemplary embodiment, the lubricant ismechanically bonded to the interior surfaces of the tubular members. Inan exemplary embodiment, the lubricant is adhesively bonded to theinterior surface of the tubular members. In an exemplary embodiment, thelubricant includes epoxy, molybdenum disulfide, graphite, aluminum,copper, alumisilicate and polyethylenepolyamine.

A method of coupling a tubular member to a preexisting structure hasalso been described that includes positioning the tubular member and anexpansion cone within the preexisting structure, anchoring the tubularmember to the preexisting structure, and axially displacing theexpansion cone relative to the tubular member by pulling the expansioncone through the tubular member. The tubular member preferably includes:an annular member, including: a wall thickness that varies less thanabout 8%, a hoop yield strength that varies less than about 10%,imperfections of less than about 8% of the wall thickness, no failurefor radial expansions of up to about 30%, and no necking of the walls ofthe annular member for radial expansions of up to about 25%.

A method of coupling a tubular member to a preexisting structure hasalso been described that includes injecting a lubricating fluid into thepreexisting structure, positioning the tubular member and an expansioncone within the preexisting structure, anchoring the tubular member tothe preexisting structure, and axially displacing the expansion conerelative to the tubular member by pulling the expansion cone through thetubular member. In an exemplary embodiment, the lubricating fluidincludes: BARO-LUB GOLD-SEALJ brand drilling mud lubricant.

A method of coupling an expandable tubular member to a preexistingstructure has also been described that includes positioning theexpandable tubular member and an expansion cone within the preexistingstructure, anchoring the expandable tubular member to the preexistingstructure, and

-   -   axially displacing the expansion cone relative to the expandable        tubular member by pulling the expansion cone through the        expandable tubular member. In an exemplary embodiment, the        expandable tubular member includes: a first tubular member, a        second tubular member, and a threaded connection for coupling        the first tubular member to the second tubular member. In an        exemplary embodiment, the threaded connection includes: one or        more sealing members for sealing the interface between the first        and second tubular members. In an exemplary embodiment, the        threaded connection includes a pin and box threaded connection.        In an exemplary embodiment, the sealing members are positioned        adjacent to an end portion of the threaded connection. In an        exemplary embodiment, one of the sealing members is positioned        adjacent to an end portion of the threaded connection; and        wherein another one of the sealing members is not positioned        adjacent to an end portion of the threaded connection. In an        exemplary embodiment, a plurality of the sealing members are        positioned adjacent to an end portion of the threaded        connection.

A method of coupling an expandable tubular member to a preexistingstructure has also been described that includes positioning theexpandable tubular member and an expansion cone within the preexistingstructure, anchoring the expandable tubular member to the preexistingstructure, and axially displacing the expansion cone relative to theexpandable tubular member by pulling the expansion cone through theexpandable tubular member. In an exemplary embodiment, the expandabletubular member includes a plurality of tubular members having threadedportions that are coupled to one another by the process of: coating thethreaded portions of the tubular members with a sealant, coupling thethreaded portions of the tubular members, and curing the sealant. In anexemplary embodiment, the sealant is selected from the group consistingof epoxies, thermosetting sealing compounds, curable sealing compounds,and sealing compounds having polymerizable materials. In an exemplaryembodiment, the method further includes: initially curing the sealantprior to radially expanding the tubular members, and finally curing thesealant after radially expanding the tubular members. In an exemplaryembodiment, the sealant can be stretched up to about 30 to 40 percentafter curing without failure. In an exemplary embodiment, the sealant isresistant to conventional wellbore fluidic materials. In an exemplaryembodiment, the material properties of the sealant are substantiallystable for temperatures ranging from about 0 to 450 EF. In an exemplaryembodiment, the method further includes: applying a primer to thethreaded portions of the tubular members prior to coating the threadedportions of the tubular members with the sealant. In an exemplaryembodiment, the primer includes a curing catalyst. In an exemplaryembodiment, the primer is applied to the threaded portion of one of thetubular members and the sealant is applied to the threaded portion ofthe other one of the tubular members. In an exemplary embodiment, theprimer includes a curing catalyst.

A method of coupling a tubular member to a preexisting structure hasalso been described that includes positioning the tubular member and anexpansion cone within the preexisting structure, anchoring the tubularmember to the preexisting structure, and axially displacing theexpansion cone relative to the tubular member by pulling the expansioncone through the expandable tubular member. In an exemplary embodiment,the tubular member includes: a pair of rings for engaging thepreexisting structure, and a sealing element positioned between therings for sealing the interface between the tubular member and thepreexisting structure.

A method of coupling a tubular member to a preexisting structure hasalso been described that includes positioning the expandable tubularmember and an expansion cone within the preexisting structure, anchoringthe expandable tubular member to the preexisting structure, and axiallydisplacing the expansion cone relative to the expandable tubular memberby pulling the expansion cone through the expandable tubular member. Inan exemplary embodiment, the tubular member includes one or more slots.In an exemplary embodiment, the slots are provided at a preexpandedportion of the tubular member. In an exemplary embodiment, the slots areprovided at a non-preexpanded portion of the tubular member.

A method of coupling a tubular member to a preexisting structure hasalso been described that includes positioning the expandable tubularmember and an expansion cone within the preexisting structure, anchoringthe expandable tubular member to the preexisting structure, and axiallydisplacing the expansion cone relative to the expandable tubular memberby pulling the expansion cone through the expandable tubular member. Inan exemplary embodiment, the tubular member includes: a firstpreexpanded portion, an intermediate portion coupled to the firstpreexpanded portion including a sealing element, and a secondpreexpanded portion coupled to the intermediate portion.

A method of coupling a tubular member to a preexisting structure hasalso been described that includes positioning the expandable tubularmember and an expansion cone within the preexisting structure, anchoringthe expandable tubular member to the preexisting structure, and axiallydisplacing the expansion cone relative to the expandable tubular memberby pulling the expansion cone through the expandable tubular member byapplying an axial force to the expansion cone. The axial forcepreferably includes a substantially constant axial force, and anincreased axial force. In an exemplary embodiment, the increased axialforce is provided on a periodic basis. In an exemplary embodiment, theincreased axial force is provided on a random basis. In an exemplaryembodiment, the ratio of the increased axial force to the substantiallyconstant axial force ranges from about 5 to 40%.

A method of coupling a tubular member to a preexisting structure hasalso been described that includes positioning the tubular member and anexpansion cone within the preexisting structure, anchoring the tubularmember to the preexisting structure, and axially displacing theexpansion cone relative to the expandable tubular member by pushing andpulling the expansion cone through the expandable tubular member. In anexemplary embodiment, pushing the expansion cone includes: injecting apressurized fluidic material into contact with the expansion cone.

A method of coupling a tubular member to a preexisting structure hasalso been described that includes positioning the tubular member and anexpansion cone within the preexisting structure, anchoring the tubularmember to the preexisting structure, axially displacing the expansioncone relative to the tubular member by pulling the expansion conethrough the expandable tubular member, and injecting a curable fluidicsealing material between the tubular member and the preexistingstructure prior to axially displacing the expansion cone.

A method of coupling a tubular member to a preexisting structure hasalso been described that includes positioning the tubular member and anexpansion cone within the preexisting structure, anchoring the tubularmember to the preexisting structure by increasing the size of theexpansion cone, and axially displacing the expansion cone relative tothe tubular member by pulling the expansion cone through the tubularmember.

A method of coupling a tubular member to a preexisting structure hasalso been described that includes positioning the tubular member and anexpansion cone within the preexisting structure, anchoring the tubularmember to the preexisting structure by heating a portion of the tubularmember, and axially displacing the expansion cone relative to thetubular member by pulling the expansion cone through the tubular member.

A method of coupling an expandable tubular member to a preexistingstructure has also been described that includes positioning theexpandable tubular member, an expansion cone, and an anchoring devicewithin the preexisting structure, positioning the anchoring device abovethe expansion cone, anchoring the expandable tubular member to thepreexisting structure using the anchoring device, and axially displacingthe expansion cone.

A method of coupling an expandable tubular member to a preexistingstructure has also been described that includes positioning the tubularmember and an expansion cone within the preexisting structure,explosively anchoring the tubular member to the preexisting structure,and axially displacing the expansion cone relative to the tubularmember.

A method of coupling an expandable tubular to a preexisting structurehas also been described that includes fixing the position of anexpansion cone within the preexisting structure, driving the expandabletubular member onto the expansion cone in a first direction, and axiallydisplacing the expansion cone in a second direction relative to theexpandable tubular member. In an exemplary embodiment, the first andsecond directions are different.

A method of coupling an expandable tubular member to a preexistingstructure has also been described that includes placing the expandabletubular, an expansion cone, and a resilient anchor within thepreexisting structure, releasing the resilient anchor, and axiallydisplacing the expansion cone within the expandable tubular member.

A method of coupling an expandable tubular member to a preexistingstructure has also been described that includes placing the expandabletubular member, an expansion cone, and an anchor into the preexistingstructure, anchoring the expandable tubular member to the preexistingstructure by: pivoting one or more engagement elements, and axiallydisplacing the expansion cone. In an exemplary embodiment, pivoting theengagement elements includes: actuating the engagement elements. In anexemplary embodiment, pivoting the engagement elements includes: placinga quantity of a fluidic material onto the engagement elements. In anexemplary embodiment, pivoting the engagement elements includes:displacing the expandable tubular member.

A method of coupling an expandable tubular member to a preexistingstructure has also been described that includes placing the expandabletubular member and an expansion cone into the preexisting structure,placing a quantity of a fluidic material onto the expandable tubularmember to anchor the expandable tubular member to the preexistingstructure, and axially displacing the expansion cone. In an exemplaryembodiment, the fluidic material includes a barite plug. In an exemplaryembodiment, the fluidic material includes a flex plug.

A method of coupling an expandable tubular member to a preexistingstructure has also been described that includes positioning theexpandable tubular member and an expansion cone into the preexistingstructure, anchoring the expandable tubular member to the preexistingstructure by injecting a quantity of a hardenable fluidic material intothe preexisting structure, at least partially curing the hardenablefluidic sealing material, and

-   -   axially displacing the expansion cone.

A method of coupling an expandable tubular member to a preexistingstructure has also been described that includes placing the expandabletubular member and an expansion cone within the preexisting structure,and applying an axial force to the expandable tubular member in adownward direction.

A method of coupling an expandable tubular member to a preexistingstructure has also been described that includes placing the expandabletubular member and an expansion cone within the preexisting structure,injecting a quantity of a first fluidic material having a first densityinto the region of the preexisting structure outside of the expandabletubular member, and injecting a quantity of a second fluidic materialhaving a second density into a portion of the expandable tubular memberbelow the expansion cone. In an exemplary embodiment, the second densityis greater than the first density.

A method of coupling an expandable tubular member to a preexistingstructure has also been described that includes placing the expandabletubular member and an expansion cone into the preexisting structure,anchoring the expandable tubular member to the preexisting structure,applying an axial force to the expansion cone, and pressurizing aninterior portion of the expandable tubular member below the expansioncone.

A method of coupling an expandable tubular member to a preexistingstructure has also been described that includes placing the expandabletubular member and an expansion cone into the preexisting structure, andapplying an axial force to the expandable tubular member.

An apparatus for coupling a tubular member to a preexisting structurehas also been described that includes an expandable tubular member, ananchoring device adapted to couple the expandable tubular member to thepreexisting structure, and an expansion cone movably coupled to theexpandable tubular member and adapted to radially expand the expandabletubular member, including: a housing including a tapered first end and asecond end, one or more grooves formed in the outer surface of thetapered first end, and one or more axial flow passages fluidicly coupledto the grooves. In an exemplary embodiment, the grooves includecircumferential grooves. In an exemplary embodiment, the grooves includespiral grooves. In an exemplary embodiment, the grooves are concentratedaround the axial midpoint of the tapered portion of the housing. In anexemplary embodiment, the axial flow passages include axial grooves. Inan exemplary embodiment, the axial grooves are spaced apart by at leastabout 3 inches in the circumferential direction. In an exemplaryembodiment, the axial grooves extend from the tapered first end of thebody to the grooves. In an exemplary embodiment, the axial groovesextend from the second end of the body to the grooves. In an exemplaryembodiment, the axial grooves extend from the tapered first end of thebody to the second end of the body. In an exemplary embodiment, theaxial flow passages are positioned within the housing of the expansioncone. In an exemplary embodiment, the axial flow passages extend fromthe tapered first end of the body to the grooves. In an exemplaryembodiment, the axial flow passages extend from the tapered first end ofthe body to the second end of the body. In an exemplary embodiment, theaxial flow passages extend from the second end of the body to thegrooves. In an exemplary embodiment, one or more of the flow passagesinclude inserts having restricted flow passages. In an exemplaryembodiment, one or more of the axial flow passages include filters. Inan exemplary embodiment, the cross sectional area of the grooves isgreater than the cross sectional area of the axial flow passages. In anexemplary embodiment, the cross-sectional area of the grooves rangesfrom about 2×10⁻⁴ in to 5×10⁻² in². In an exemplary embodiment, thecross-sectional area of the axial flow passages ranges from about 2×10⁻⁴in² to 5×10⁻² in². In an exemplary embodiment, the angle of attack ofthe first tapered end of the body ranges from about 10 to 30 degrees. Inan exemplary embodiment, the grooves are concentrated in a trailing edgeportion of the tapered first end. In an exemplary embodiment, the angleof inclination of the axial flow passages relative to the longitudinalaxis of the expansion cone is greater than the angle of attack of thefirst tapered end. In an exemplary embodiment, the grooves include: aflow channel having a first radius of curvature, a first shoulderpositioned on one side of the flow channel having a second radius ofcurvature, and a second shoulder positioned on the other side of theflow channel having a third radius of curvature. In an exemplaryembodiment, the first, second and third radii of curvature aresubstantially equal. In an exemplary embodiment, the axial flow passagesinclude: a flow channel having a first radius of curvature, a firstshoulder positioned on one side of the flow channel having a secondradius of curvature, and a second shoulder positioned on the other sideof the flow channel having a third radius of curvature. In an exemplaryembodiment, the first, second and third radii of curvature aresubstantially equal. In an exemplary embodiment, the second radius ofcurvature is greater than the third radius of curvature.

An apparatus for coupling an expandable tubular member to a preexistingstructure has also been described that includes an expandable tubularmember, an anchoring device adapted to couple the expandable tubularmember to the preexisting structure, and an expansion cone movablycoupled to the expandable tubular member and adapted to radially expandthe expandable tubular member. In an exemplary embodiment, theexpandable tubular member includes: an annular member, having: a wallthickness that varies less than about 8%, a hoop yield strength thatvaries less than about 10%; imperfections of less than about 8% of thewall thickness, no failure for radial expansions of up to about 30%, andno necking of the walls of the annular member for radial expansions ofup to about 25%.

An apparatus for coupling an expandable tubular member to a preexistingstructure has also been described that includes an expandable tubularmember, an anchoring device adapted to couple the expandable tubularmember to the preexisting structure, and an expansion cone movablycoupled to the expandable tubular member and adapted to radially expandthe expandable tubular member. In an exemplary embodiment, theexpandable tubular member includes: a first tubular member, a secondtubular member, and a threaded connection for coupling the first tubularmember to the second tubular member. In an exemplary embodiment, thethreaded connection includes: one or more sealing members for sealingthe interface between the first and second tubular members. In anexemplary embodiment, the threaded connection includes a pin and boxthreaded connection. In an exemplary embodiment, the sealing members arepositioned adjacent to an end portion of the threaded connection. In anexemplary embodiment, one of the sealing members is positioned adjacentto an end portion of the threaded connection, and another one of thesealing members is not positioned adjacent to an end portion of thethreaded connection. In an exemplary embodiment, the plurality of thesealing members are positioned adjacent to an end portion of thethreaded connection.

An apparatus for coupling an expandable tubular member to a preexistingstructure has also been described that includes an expandable tubularmember, an anchoring device adapted to couple the expandable tubularmember to the preexisting structure, and an expansion cone movablycoupled to the expandable tubular member and adapted to radially expandthe expandable tubular member. In an exemplary embodiment, theexpandable tubular member includes: a layer of a lubricant coupled tothe interior surface of the tubular member. In an exemplary embodiment,the lubricant includes a metallic soap. In an exemplary embodiment, thelubricant is selected from the group consisting of C-Lube-10,C-PHOS-58-M, and C-PHOS-58-R. In an exemplary embodiment, the lubricantprovides a sliding friction coefficient of less than about 0.20. In anexemplary embodiment, the lubricant is chemically bonded to the interiorsurface of the expandable tubular member. In an exemplary embodiment,the lubricant is mechanically bonded to the interior surface of theexpandable tubular member. In an exemplary embodiment, the lubricant isadhesively bonded to the interior surface of the expandable tubularmember. In an exemplary embodiment, the lubricant includes epoxy,molybdenum disulfide, graphite, aluminum, copper, alumisilicate andpolyethylenepolyamine.

An apparatus for coupling an expandable tubular member to a preexistingstructure has also been described that includes an expandable tubularmember, an anchoring device adapted to couple the expandable tubularmember to the preexisting structure, and an expansion cone movablycoupled to the expandable tubular member and adapted to radially expandthe expandable tubular member. In an exemplary embodiment, theexpandable tubular member includes: a pair of tubular members havingthreaded portions coupled to one another, and a quantity of a sealantwithin the threaded portions of the tubular members. In an exemplaryembodiment, the sealant is selected from the group consisting ofepoxies, thermosetting sealing compounds, curable sealing compounds, andsealing compounds having polymerizable materials. In an exemplaryembodiment, the sealant includes an initial cure cycle and a final curecycle. In an exemplary embodiment, the sealant can be stretched up toabout 30 to 40 percent without failure. In an exemplary embodiment, thesealant is resistant to conventional wellbore fluidic materials. In anexemplary embodiment, the material properties of the sealant aresubstantially stable for temperatures ranging from about 0 to 450 EF. Inan exemplary embodiment, the threaded portions of the tubular membersinclude a primer for improving the adhesion of the sealant to thethreaded portions.

An apparatus for coupling an expandable tubular member to a preexistingstructure has also been described that includes an expandable tubularmember, an anchoring device adapted to couple the expandable tubularmember to the preexisting structure, and an expansion cone movablycoupled to the expandable tubular member and adapted to radially expandthe expandable tubular member. In an exemplary embodiment, theexpandable tubular member includes: a pair of rings for engaging thepreexisting structure, and a sealing element positioned between therings for sealing the interface between the tubular member and thepreexisting structure.

An apparatus for coupling an expandable tubular member to a preexistingstructure has also been described that includes an expandable tubularmember, an anchoring device adapted to couple the expandable tubularmember to the preexisting structure, and an expansion cone movablycoupled to the expandable tubular member and adapted to radially expandthe expandable tubular member. In an exemplary embodiment, theexpandable tubular member includes one or more slots. In an exemplaryembodiment, the slots are provided at a preexpanded portion of theexpandable tubular member. In an exemplary embodiment, the slots areprovided at a non-preexpanded portion of the tubular member.

An apparatus for coupling an expandable tubular member to a preexistingstructure has also been described that includes an expandable tubularmember, an anchoring device adapted to couple the expandable tubularmember to the preexisting structure, and an expansion cone movablycoupled to the expandable tubular member and adapted to radially expandthe expandable tubular member. In an exemplary embodiment, theexpandable tubular member includes: a first preexpanded portion, anintermediate portion coupled to the first preexpanded portion includinga sealing element, and a second preexpanded portion coupled to theintermediate portion.

An apparatus for coupling an expandable tubular member to a preexistingstructure has also been described that includes an expandable tubularmember, an anchoring device adapted to couple the expandable tubularmember to the preexisting structure, an expansion cone movably coupledto the expandable tubular member and adapted to radially expand theexpandable tubular member, and a valveable fluid passage coupled to theanchoring device.

An apparatus for coupling an expandable tubular member to a preexistingstructure has also been described that includes a first support member,a second support member coupled to the first support member, anexpansion cone coupled to the first support member, an expandabletubular member coupled to the expansion cone, and an anchoring devicecoupled to the second support member adapted to couple the expandabletubular member to the preexisting structure. In an exemplary embodiment,the anchoring device is positioned above the expansion cone. In anexemplary embodiment, the outside diameter of the expansion cone isgreater than the inside diameter of the expandable tubular member. In anexemplary embodiment, the outside diameter of the expansion cone isapproximately equal to the outside diameter of the expandable tubularmember.

An apparatus for coupling an expandable tubular member to a preexistingstructure has also been described that includes a first support member,a second support member coupled to the first support member, anexpansion cone coupled to the first support member, an expandabletubular member coupled to the expansion cone, and an explosive anchoringdevice coupled to the second support member adapted to couple theexpandable tubular member to the preexisting structure.

An apparatus for coupling an expandable tubular member to a preexistingstructure has also been described that includes a support member, anexpandable expansion cone coupled to the support member, and anexpandable tubular member coupled to the expansion cone.

An apparatus for coupling an expandable tubular member to a preexistingstructure has also been described that includes a support member, anexpandable expansion cone coupled to the support member, and anexpandable tubular member coupled to the expandable expansion cone. Inan exemplary embodiment, the expandable tubular member includes one ormore anchoring devices. In an exemplary embodiment, the expandabletubular member includes a slotted end portion.

An apparatus for coupling an expandable tubular to a preexistingstructure has also been described that includes a support member, anexpansion cone coupled to the support member, an expandable tubularmember coupled to the expansion cone including one or more shape memorymetal inserts, and a heater coupled to the support member in opposingrelation to the shape memory metal inserts.

An apparatus for coupling an expandable tubular member to a preexistingstructure has also been described that includes a support member,

-   -   an expansion cone coupled to the support member, an expandable        tubular member coupled to the expandable expansion cone, and a        resilient anchor coupled to the expandable tubular member. In an        exemplary embodiment, the resilient anchor includes a resilient        scroll. In an exemplary embodiment, the resilient anchor        includes one or more resilient arms. In an exemplary embodiment,        the resilient anchor includes: one or more resilient radially        oriented elements. In an exemplary embodiment, the resilient        anchor is adapted to mate with the expansion cone.

An expandable tubular member has also been described that includes anexpandable tubular body, one or more resilient panels coupled to theexpandable tubular body, and a release member releasably coupled to theresilient panels adapted to controllably release the resilient panels.

An apparatus for coupling an expandable tubular member to a preexistingstructure has also been described that includes a support member,

-   -   an expansion cone coupled to the support member, an expandable        tubular member coupled to the expandable expansion cone, and an        anchor coupled to the expandable tubular member, including: one        or more spikes pivotally coupled to the expandable tubular        member for engaging the preexisting structure. In an exemplary        embodiment, the apparatus further includes one or more        corresponding actuators for pivoting the spikes.

An apparatus for coupling an expandable tubular member to a preexistingstructure has also been described that includes a support member,

-   -   an expansion cone coupled to the support member, an expandable        tubular member coupled to the expandable expansion cone, and an        anchor coupled to the expandable tubular member, including: one        or more petal baskets pivotally coupled to the expandable        tubular member. In an exemplary embodiment, the apparatus        further includes one or more corresponding actuators for        pivoting the petal baskets.

An apparatus for coupling an expandable tubular member to a preexistingstructure has also been described that includes a support member, anexpansion cone coupled to the support member, an expandable tubularmember coupled to the expansion cone, including: a slotted portionprovided at one end of the expandable tubular member.

An apparatus for coupling an expandable tubular member to a preexistingstructure has also been described that includes a support member, anexpansion cone, an expandable tubular member coupled to the expansioncone, a coupling device coupled to the support member and an end portionof the expandable tubular member, and a mass coupled to the end portionof the expandable tubular member. In an exemplary embodiment, the weightof the mass is greater than about 50 to 100% of the yield strength ofthe expandable tubular member.

An apparatus for coupling an expandable tubular member to a preexistingstructure has also been described that includes a support memberincluding a fluid passage, an expansion cone coupled to the supportmember, an expandable tubular member coupled to the expansion cone, aslip joint coupled to the expansion cone, an end plate coupled to theslip joint, a fluid chamber coupled to the fluid passage, the fluidchamber defined by the interior portion of the expandable tubular memberbetween the expansion cone and the end plate.

A method of coupling a tubular member to a preexisting structure hasbeen described that includes positioning the tubular member and anexpansion cone within the preexisting structure, axially displacing theexpansion cone, removing the expansion cone, and applying direct radialpressure to the first tubular member. In an exemplary embodiment,axially displacing the expansion cone includes pressurizing at least aportion of the interior of the tubular member. In an exemplaryembodiment, axially displacing the expansion cone includes: injecting afluidic material into the tubular member. In an exemplary embodiment,axially displacing the expansion cone includes: applying a tensile forceto the expansion cone. In an exemplary embodiment, axially displacingthe expansion cone includes: displacing the expansion cone into thetubular member. In an exemplary embodiment, axially displacing theexpansion cone includes: displacing the expansion cone out of thetubular member. In an exemplary embodiment, axially displacing theexpansion cone radially expands the tubular member by about 10% to 20%.In an exemplary embodiment, applying direct radial pressure to the firsttubular member radially expands the tubular member by up to about 5%. Inan exemplary embodiment, applying direct radial pressure to the tubularmember includes applying a radial force at discrete locations. In anexemplary embodiment, the preexisting structure includes a wellborecasing. In an exemplary embodiment, the preexisting structure includes apipeline. In an exemplary embodiment, the preexisting structure includesa structural support.

An apparatus also has been described that includes a tubular membercoupled to a preexisting structure. The tubular member is coupled to thepreexisting structure by the process of: positioning the tubular memberand an expansion cone within the preexisting structure, axiallydisplacing the expansion cone, removing the expansion cone, and applyingdirect radial pressure to the tubular member. In an exemplaryembodiment, axially displacing the expansion cone includes: pressurizingat least a portion of the interior of the tubular member. In anexemplary embodiment, axially displacing the expansion cone includes:injecting a fluidic material into the tubular member. In an exemplaryembodiment, axially displacing the expansion cone includes: applying atensile force to the expansion cone. In an exemplary embodiment, axiallydisplacing the expansion cone includes: displacing the expansion coneinto the tubular member. In an exemplary embodiment, axially displacingthe expansion cone includes: displacing the expansion cone out of thetubular member. In an exemplary embodiment, axially displacing theexpansion cone radially expands the tubular member by about 10% to 20%.In an exemplary embodiment, applying direct radial pressure to thetubular member radially expands the tubular member by up to about 5%. Inan exemplary embodiment, applying direct radial pressure to the tubularmember includes applying a radial force at discrete locations. In anexemplary embodiment, the preexisting structure includes a wellborecasing. In an exemplary embodiment, the preexisting structure includes apipeline. In an exemplary embodiment, the preexisting structure includesa structural support.

Although this detailed description has shown and described illustrativeembodiments of the invention, this description contemplates a wide rangeof modifications, changes, and substitutions. In some instances, one mayemploy some features of the present invention without a correspondinguse of the other features. Accordingly, it is appropriate that readersshould construe the appended claims broadly, and in a manner consistentwith the scope of the invention.

1. An apparatus for coupling a tubular member to a preexistingstructure, comprising: a support member; an expansion member coupled tothe support member; a tubular member coupled to the expansion membercomprising one or more shape memory metal inserts; and a heater coupledto the support member proximate the shape memory metal inserts; wherein,the support member, the expansion member, and the heater are positionedwithin the preexisting structure.
 2. The apparatus of claim 1, whereinthe shape memory metal inserts are coupled to an end portion of thetubular member.
 3. The apparatus of claim 1, wherein the composition ofan end portion of the tubular member is selected to maximize a radialexpansion of the end portion of the tubular member.
 4. The apparatus ofclaim 3, wherein the composition of an end portion of the tubular memberis selected to maximize a radial expansion of the end portion of thetubular member during an operation of the heater.
 5. A method ofcoupling a tubular member to a preexisting structure, comprising:positioning the tubular member, a shape memory metal, and an expansiondevice within the preexisting structure; anchoring the tubular member tothe preexisting structure using the shape memory metal; and radiallyexpanding and plastically deforming the tubular member using theexpansion device.
 6. The method of claim 5, wherein anchoring thetubular member to the preexisting structure using the shape memory metalcomprises: radially expanding a portion of the tubular member intoengagement with the preexisting structure using the shape memory metal.7. The method of claim 6, wherein the composition of the portion of thetubular member is selected to maximize the radial expansion of theportion of the tubular member.
 8. The method of claim 6, wherein theportion of the tubular member comprises an end portion of the tubularmember.
 9. The method of claim 5, wherein the composition of an endportion of the tubular member is selected to maximize the radialexpansion of the end portion of the tubular member.
 10. A system forcoupling a tubular member to a preexisting structure, comprising: meansfor positioning the tubular member, a shape memory metal, and anexpansion device within the preexisting structure; means for anchoringthe tubular member to the preexisting structure using the shape memorymetal; and means for radially expanding and plastically deforming thetubular member using the expansion device.
 11. The system of claim 10,wherein means for anchoring the tubular member to the preexistingstructure using the shape memory metal comprises: means for radiallyexpanding and plastically deforming a portion of the tubular member intoengagement with the preexisting structure using the shape memory metal.12. The system of claim 11, wherein the composition of the portion ofthe tubular member is selected to maximize the radial expansion of theportion of the tubular member.
 13. The system of claim 11, wherein theportion of the tubular member comprises an end portion of the tubularmember.
 14. The system of claim 10, wherein the composition of an endportion of the tubular member is selected to maximize the radialexpansion of the end portion of the tubular member.
 15. An apparatus,comprising: an expandable tubular member; and means for radiallyexpanding an end portion of the expandable tubular member; wherein thecomposition of the end portion of the expandable tubular member isselected to maximize the radial expansion of the end portion of theexpandable tubular member.
 16. A system for radially expanding a tubularmember, comprising: means for radially expanding the tubular member; andmeans for maximizing the radial expansion of an end portion of thetubular member.
 17. A method of radially expanding a tubular member,comprising: fabricating a tubular member having an end portioncomprising a composition that maximizes the amount of radial expansionof the end portion when an expansion force is applied to the endportion.
 18. The method of claim 17, further comprising: radiallyexpanding the end portion of the tubular member; and then radiallyexpanding the remaining portion of the tubular member.
 19. The method ofclaim 18, wherein the expansion forces required to radially expand theend portion of the tubular member are less than the expansion forcesrequired to radially expand the remaining portion of the tubular member.20. An expandable tubular member, comprising: an end portion comprisinga composition that maximizes the amount of radial expansion of the endportion when an expansion force is applied to the end portion; and aremaining portion coupled to the end portion.